Converting lines and methods for fabricating both taped and pant diapers comprising substantially identical chassis

ABSTRACT

The present disclosure relates to taped and pant articles comprising substantially identical chassis.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.13/372,940, filed Feb. 14, 2012, which is a continuation-in-part of U.S.application Ser. No. 13/371,919, filed on Feb. 13, 2012, which is acontinuation-in-part of U.S. application Ser. No. 13/074,058, filed onMar. 29, 2011, which claims the benefit of U.S. Provisional ApplicationNo. 61/322,359, filed on Apr. 9, 2010, the substances of which arehereby incorporated by reference.

FIELD OF THE INVENTION

The present disclosure relates to converting lines for manufacturingdisposable taped and pant absorbent articles.

BACKGROUND OF THE INVENTION

Disposable, reusable and durable products such as diapers, adultincontinence articles, feminine hygiene tampons, sanitary napkins,underpants, shirts, shorts, swimsuits, gowns, pants, coats, gloves,scarves, surgical drapes, bibs, blankets, sheets, pillow cases, etc. maybe manufactured on high speed converting lines. Such converting linesmay utilize a web-based carrier to which many source materials, whetherin a continuous web or discrete pieces, are processed and/or attached tothe web to create a finished product.

Although a converting line may allow for high speed production of aspecific type of absorbent article, some converting lines may beinflexible in that line changes that would be required to accommodatethe production of different types of products would be so time consumingand/or expensive as to be economically impractical. For instance, someconverting lines are custom designed and built to make specific productswithin a narrow range of parameters and operating conditions. Forexample, converting lines may be custom designed to make only tapeddiapers, whereas other converting lines may be custom designed to makeonly pant diapers. Thus, such custom converting lines may be used toproduce particular types of diapers, e.g. taped or pant, in certainmarkets in an effort to provide a good match with business needs.However, the inflexibility of such converting lines to produce more thanone type of product can place unwanted limitations on a manufacturer'sability to provide multiple product offerings in some markets.

In markets having consumer demand for both taped diapers and pantdiapers, a manufacturer may be required to have separate convertinglines, each custom designed to produce one of the two products. However,consumer demand of one or both of the products may not be high enough tojustify the manufacturer's cost of having separate converting linesdedicated to each of the product types. For example, if the demand forpant diapers in a particular market is not high enough to justify thecost of a converting line that produces only pant diapers, themanufacture may decide not to offer pant diapers in the market. In suchmarkets, the flexibility to produce both products on the same convertingline and therefore produce the proper mix of product to meet the marketneeds may provide the most efficient and cost effective approach.

In some markets, disposable taped diapers are used for infants frombirth to a point when infants begin potty training. As an alternative totaped diapers, disposable pant diapers may be desirable and usefulproducts for children in the potty training stage. In yet otherinstances, the use of pant diapers may start at an earlier age than agestypically associated with potty training, and therefore, pant diapersmay be used more like a taped diaper than a training pant. Onedifference between taped diapers and pant diapers is how the twoproducts are delivered from the manufacturer to the consumer, i.e.packaged. In particular, both taped diapers and pant diapers cangenerally include an absorbent chassis having a liquid impervious outercover, a liquid pervious body-side liner, and an absorbent structure.However, a taped diaper may not have a closed initial waist openingcircumference or leg openings prior to being removed from the package,whereas the absorbent chassis and/or the side panels (when present) of apant diaper may be pre-closed to form an initial waist openingcircumference and two leg openings. Since the percentage of users thatprefer taped diapers versus a pant style, pull-on, diaper varies marketto market it may be advantageous for a manufacturer to have theflexibility to produce both a taped diaper and a pant, pull-on, diaperon the same converting line in any desired ratio to meet the needs tothe intended market.

Some attempts have been made to create converting lines that are capableof producing more than one type of diaper, such as disclosed in U.S.Patent Publication No. 2007/0213678A1. However, such converting linesrepresent a mere conglomeration or assembly of different convertinglines designed to build specific types of diapers. These convertinglines may utilize a relatively low number of the same processes andmachinery when producing different types of diapers. Thus, a relativelylarge number of different processes and machinery in such convertinglines are either turned-on or turned-off depending on what type ofdiaper is being produced. As such, a converting line that includes arelatively large number of processes that may not be used when producingdifferent types of diapers may result in large capital costs, requirelarge amounts of space and require additional maintenance.

Thus, there remains a need to develop a converting line that is capableof producing different types of diapers while at the same time utilizinga substantial number of the same processes and machinery to produceeither the range of diaper types resulting in greater efficiency andlower overall cost.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a partially cut away plan view of a taped diaper with theportion of the diaper that faces away from a wearer oriented towards theviewer.

FIG. 1A is plan view of the taped diaper of FIG. 1 with the portion ofthe diaper that faces away toward a wearer oriented towards the viewer.

FIG. 2 is a partially cut away plan view of a pant diaper with a pair ofside panels.

FIG. 3 is a partially cut away plan view a pant diaper with front andrear side ear panels.

FIG. 4 is a perspective of the taped diaper shown in FIG. 1 in a foldedconfiguration.

FIG. 5 is a perspective view the pant diaper shown in FIG. 2 with sidepanels connecting opposing waist regions.

FIG. 6 is a perspective view the pant diaper shown in FIG. 3 with sideseams connecting the ear panels and opposing waist regions.

FIG. 7 is a perspective view of a pant diaper with side panels tuckedinto the interior of a chassis.

FIG. 8 is a schematic side view of a converting apparatus in a first,taped diaper, configuration adapted to manufacture taped diapers.

FIG. 8A is a partial detailed view of FIG. 8 showing transformations ofparticular processes.

FIG. 8B is a partial detailed view of FIG. 8 showing transformations ofparticular processes.

FIG. 8C is an example flow diagram showing various transformations thatmay be used to construct a taped diaper as well as a pant diaper.

FIG. 9 is a schematic side view of a converting apparatus in a second,pant diaper, configuration adapted to manufacture pant diapers.

FIG. 10 is a schematic side view of a converting apparatus in a third,pant diaper, configuration adapted to manufacture pant diapers with sideseams.

FIG. 11 is a perspective view of a side panel connection apparatus.

FIG. 12 shows a cross-sectional view of a side panel tucking apparatusand pant diaper.

FIG. 13 shows a cross-sectional view of the apparatus and a pant diaperof FIG. 12 with the side panels being tucked.

FIG. 14 shows a cross-sectional view of a tucking apparatus utilizingrotating tucker blades and pant diaper of FIG. 13 taken along line14-14.

FIG. 15 show a cross-sectional view of a tucking apparatus utilizing airjets and diaper pant of FIG. 13 taken along line 14-14.

FIG. 16 is a top plan view of a nonwoven specimen for an inner cuff.

FIG. 17A is the nonwoven specimen of FIG. 16 including a glue pattern.

FIG. 17B is the nonwoven specimen of FIG. 17A including elastic strands.

FIG. 18 is a cross-sectional view of an inner cuff with a continuous hembond.

FIG. 19 is a top plan view of a nonwoven specimen for an outer cuff.

FIG. 20A is the nonwoven specimen of FIG. 19 including a glue pattern.

FIG. 20B is the nonwoven specimen of FIG. 20A including elastic strands.

FIG. 21 is a top plan view of a backsheet film specimen for an outercuff.

FIG. 22 is an isometric view of an outer cuff specimen.

FIG. 23 is a dimensioned view of hook-shaped fixtures used in the waiststretch test (pants) method.

FIG. 24 is a view of the hook-shaped fixtures used in the waist stretchtest (pants) method aligned in the same plane.

FIG. 25 is a plan view of an exemplary absorbent article laid out flat,suitable in one embodiment of the invention.

FIG. 25A is a schematic cross section view of a back belt-like flapsuitable in one embodiment of the invention, taken along 25A-25A of FIG.25.

FIG. 25B is a schematic cross section view of a front belt-like flapsuitable in one embodiment of the invention, taken along 25B-25B of FIG.25.

FIG. 26 is a schematic cross section view of an exemplary absorbentarticle, suitable in one embodiment of the invention.

FIG. 27 is a schematic cross section view of an exemplary absorbentarticle, suitable in one embodiment of the invention.

FIG. 28 is a schematic cross section view of an exemplary absorbentarticle, suitable in one embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION

The following term explanations may be useful in understanding thepresent disclosure:

“Absorbent article” is used herein to refer to consumer products whoseprimary function is to absorb and retain soils and wastes. “Diaper” isused herein to refer to an absorbent article generally worn by infantsand incontinent persons about the lower torso. The term “disposable” isused herein to describe absorbent articles which generally are notintended to be laundered or otherwise restored or reused as an absorbentarticle (e.g., they are intended to be discarded after a single use andmay also be configured to be recycled, composted or otherwise disposedof in an environmentally compatible manner).

The term “disposed” is used herein to mean that an element(s) is formed(joined and positioned) in a particular place or position as amacro-unitary structure with other elements or as a separate elementjoined to another element.

As used herein, the term “joined” encompasses configurations whereby anelement is directly secured to another element by affixing the elementdirectly to the other element, and configurations whereby an element isindirectly secured to another element by affixing the element tointermediate member(s) which in turn are affixed to the other element.

The term “substrate” is used herein to describe a material which isprimarily two-dimensional (i.e. in an XY plane) and whose thickness (ina Z direction) is relatively small (i.e. 1/10 or less) in comparison toits length (in an X direction) and width (in a Y direction).Non-limiting examples of substrates include a web, layer or layers orfibrous materials, nonwovens, films and foils such as polymeric films ormetallic foils. These materials may be used alone or may comprise two ormore layers laminated together. As such, a web is a substrate.

The term “nonwoven” refers herein to a material made from continuous(long) filaments (fibers) and/or discontinuous (short) filaments(fibers) by processes such as spunbonding, meltblowing, carding, and thelike. Nonwovens do not have a woven or knitted filament pattern.

The term “machine direction” (MD) is used herein to refer to the primarydirection of material flow through a process. In various manufacturingand converting processes, such as a bi-fold process, it may be possibleto have more than one machine direction when an article is undergoingsimultaneous processes. In other words, a manufacturing line may have anoverall machine direction, but an article may travel in directions otherthan the overall machine direction as it passes through variousprocesses along the manufacturing line. For example, an article having atrailing end portion and a leading end portion, each portion beingattached to the surface of a different roll and/or conveyor, may travelin two different directions simultaneously. In this example, bothdirections of travel may be considered the machine direction. The term“cross direction” (CD) is used herein to refer to a direction that isgenerally perpendicular to the machine direction.

The term “transformation” refers herein to a change or activityresulting in a change in a web, layer, article, plurality of articles,material or portions thereof with regard to the thickness, length,width, shape, relative position, texture, color, tackiness, etc.Transformations are: fiberization, core component mixing, coreformation/deposition, slitting, cutting, notching, shaping, perforation,die cutting, trimming, thermal bonding, ultrasonic bonding, pressurebonding, radio frequency bonding, seaming, adhesive application,cohesive application, lotion application, folding, bi-folding, tucking,spacing, MD positioning, CD positioning, registration, activation,compression, nipping, calendaring, substrate combining, componentcombining, web combining, elastic tensioning, fastening elementpre-fastening, product stacking, and packaging.

The term “transformation mechanism” refers herein to an apparatusadapted to produce a transformation.

The term “taped diaper” (also referred to as “open diaper”) refers todisposable absorbent articles having an initial front waist region andan initial back waist region that are not fastened, pre-fastened, orconnected to each other as packaged, prior to being applied to thewearer. A taped diaper may be folded about the lateral centerline withthe interior of one waist region in surface to surface contact with theinterior of the opposing waist region without fastening or joining thewaist regions together. Example taped diapers are disclosed in varioussuitable configurations are disclosed in U.S. Pat. Nos. 5,167,897,5,360,420, 5,599,335, 5,643,588, 5,674,216, 5,702,551, 5,968,025,6,107,537, 6,118,041, 6,153,209, 6,410,129, 6,426,444, 6,586,652,6,627,787, 6,617,016, 6,825,393, and 6,861,571.

The term “pant” (also referred to as “training pant”, “pre-closeddiaper”, “diaper-pant”, and “pull-on diaper”) refers herein todisposable absorbent articles having a continuous perimeter waistopening and continuous perimeter leg openings designed for infant oradult wearers. A pant can be configured with a continuous or closedwaist opening and at least one continuous, closed, leg opening prior tothe article being applied to the wearer. A pant can be preformed byvarious techniques including, but not limited to, joining togetherportions of the article using any refastenable and/or permanent closuremember (e.g., seams, heat bonds, pressure welds, adhesives, cohesivebonds, mechanical fasteners, etc.). A pant can be preformed anywherealong the circumference of the article in the waist region (e.g., sidefastened or seamed, front waist fastened or seamed, rear waist fastenedor seamed). Example diaper pants in various configurations are disclosedin U.S. Pat. Nos. 5,246,433; 5,569,234; 6,120,487; 6,120,489; 4,940,464;5,092,861; 5,897,545; 5,957,908; and U.S. Patent Publication No.2003/0233082.

The term “initial waist opening circumference” refers herein to thecircumference of the waist opening at the time the pant is placed in thepackage and subsequently when it is removed from the package by theconsumer.

The present disclosure relates to converting lines for manufacturingabsorbent articles, and in particular, converting lines that arereconfigurable to produce both taped diapers and pant diapers. Asdiscussed in more detail below, an absorbent article converting line mayinclude a combination of converting mechanisms that advance substratesand component materials through a manufacturing process. While advancingin the machine direction MD through the converting line, substrates maybe modified and/or combined with the other substrates and/or discretecomponents to create a continuous length of absorbent articles. Varioussubstrates can be used to construct various components of the absorbentarticles, such as backsheets, topsheets, and absorbent cores. Exemplarydescriptions of absorbent article components with respect to both tapeddiapers and pant diapers are provided below. At a downstream portion ofthe converting process, the continuous length of absorbent articles maybe subjected to a final knife and cut to create separate and discreteabsorbent articles. In addition, defective articles may be removed fromthe process by a rejection system. Articles that are not deemed to bedefective may be subject to further processing steps, such as foldingand packaging.

Aspects of the apparatuses and methods according to the presentdisclosure relate to a converting apparatus for the fabrication ofabsorbent articles and adapted to operate in a first configuration and asecond configuration. As discussed in more detail below, the convertingapparatus includes transformation mechanisms adapted to produce a seriesof transformations. In the first configuration, a first plurality of thetransformation mechanisms are arranged to produce a plurality of tapeddiapers, wherein the first plurality of the transformation mechanismsproduce a first number of transformations. In the second configuration,a second plurality of the transformation mechanisms are arranged toproduce a plurality of pant diapers, wherein the second plurality of thetransformation mechanisms produce a second number of transformations.The converting apparatus is configured with relatively high flexibilityin changing between the first and second configurations, because greaterthan 70% of the second number of transformations are the same as thefirst number of transformations resulting in greater efficiency andequipment utilization.

In another form, the first configuration may include a first pluralityof transformation mechanisms adapted to produce a first number oftransformations, wherein the first number of transformations may becarried out in a first sequence advancing from a first transformation toa last transformation. In addition, the second configuration may includea second plurality of the transformation mechanisms adapted to produce asecond number of transformations. The second number of transformationsmay be carried out in a second sequence advancing from a firsttransformation to a last transformation. Again, the converting apparatusis configured with relatively high flexibility in changing between thefirst and second configurations, because 70% of the second number oftransformations is carried out in an identical order as the first numberof transformations with respect to one or more of precedingtransformations in the first number of transformations.

The following provides a general description of various types of tapeddiapers and pant diapers that may be produced with the methods andapparatuses disclosed herein to help provide additional context to thesubsequent discussion of the reconfigurable converting lines. Forexample, FIG. 1 shows one example of a plan view of a taped diaper 100T,with the portion of the diaper that faces away from a wearer orientedtowards the viewer. And FIG. 1A shows a plan view of the taped diaper100T with the portion of the diaper that faces toward a wearer orientedtowards the viewer. The taped diaper 100T shown in FIGS. 1 and 1Aincludes a chassis 102, first and second back ears 104 and 106; andfirst and second front ears 108 and 110. FIG. 2 shows a diaper pant 100Pin a flat, unfolded condition, with the portion of the diaper that facesaway from a wearer oriented towards the viewer. The pant diaper 100Pshown in FIG. 2 also includes a chassis 102 and opposing first andsecond side panels 112 and 114 (the first and second side panels mayalso be referred to as first and second back ears). FIG. 3 shows adiaper pant 100P and chassis 102 in a flat, unfolded condition, with theportion of the diaper that faces away from a wearer oriented towards theviewer. However, the diaper pant 100P of FIG. 3 includes first andsecond rear ear panels 112 b and 114 b, and first and second front earpanels 112 a and 114 a.

Although pant and taped diapers may have distinct different features andcomponents, it is to be appreciated that taped and pant diapers mayinclude many features and components that are substantially the same orsimilar with regard to disposition, structure, dimension, physicalappearance, etc. For the purposes of a specific illustration, variouscommon components of taped and pant diapers shown in FIGS. 1-6 aredescribed below before discussing different features and/or componentsbetween the taped and pant diapers.

As shown in FIGS. 1-3, the diapers 100T and 100P are shown as having afirst waist region 116, a second waist region 118, and a crotch region120 disposed intermediate the first and second waist regions. The firstwaist region 116 may be configured as a front waist region, and thesecond waist region 118 may be configured as back waist region. In someembodiments, the length of each of the front waist region, back waistregion, and crotch region may be ⅓ of the length of the absorbentarticle 100P and 100T. The absorbent articles 100P and 100T may eachinclude a laterally extending front waist edge 121 in the front waistregion 116 and a longitudinally opposing and laterally extending backwaist edge 122 in the back waist region 118. To provide a frame ofreference for the present discussion, the diapers 100T and 100P in FIGS.1-3 are shown with a longitudinal axis 124 and a lateral axis 126. Thelongitudinal axis 124 may extend through a midpoint of the front waistedge 121 and through a midpoint of the back waist edge 122. And thelateral axis 126 may extend through a midpoint of a first longitudinalor right side edge 128 and through a midpoint of a second longitudinalor left side edge 130.

As shown in FIGS. 1-3, the diapers 100T and 100P each include an inner,body facing surface 132, and an outer, garment facing surface 134. Thechassis 102 may include a backsheet 136 and a topsheet 138. An absorbentassembly 140 including an absorbent core 142 may be disposed between aportion of the topsheet 138 and the backsheet 136. As discussed in moredetail below, the diapers 100T and 100P may also include other features,such as leg elastics, an elastic waist region, and/or flaps, e.g. sidepanels and/or ears, to enhance the fits around the legs and waist of thewearer.

With continued reference to FIGS. 1-3, the periphery of the chassis 102may be defined by the first longitudinal side edge 128, a secondlongitudinal side edge 130; a first laterally extending end edge 144disposed in the first waist region 116; and a second laterally extendingend edge 146 disposed in the second waist region 118. Both side edges128 and 130 extend longitudinally between the front waist edge 121 andthe back waist edge 122. The laterally extending end edges 144 and 146of the chassis may form a portion of the laterally extending front waistedge 121 in the front waist region 116 and a portion of thelongitudinally opposing and laterally extending back waist edge 122 inthe back waist region 118. When either the taped diaper 100T or the pantdiaper 100P is worn on the lower torso of a wearer, the front waist edge121 and the back waist edge 122 of the chassis 102 may encircle aportion of the waist of the wearer. At the same time, the chassis sideedges 128 and 130 may encircle at least a portion of the legs of thewearer. And the crotch region 120 may be generally positioned betweenthe legs of the wearer with the absorbent core 142 extending from thefront waist region 116 through the crotch region 120 to the back waistregion 118.

It is to also be appreciated that a portion or the whole of the diapers100T and 100P may also be made laterally extensible. The additionalextensibility may help allow the diapers 100T and 100P to conform to thebody of a wearer during movement by the wearer. The additionalextensibility may also help, for example, allow the user of the diaper100T and 100P including a chassis 102 having a particular size beforeextension to extend the front waist region 116, the back waist region118, or both waist regions of the diaper 100T and 100P and/or chassis102 to provide additional body coverage for wearers of differing size,i.e. to tailor the diaper to an individual wearer. Such extension of thewaist region or regions may give the absorbent article a generallyhourglass shape, so long as the crotch region is extended to arelatively lesser degree than the waist region or regions, and mayimpart a tailored appearance to the article when it is worn.

As previously mentioned, the taped and pant diapers 100T and 100P mayinclude a backsheet 136. The backsheet 136 may also define the outersurface 134 of the chassis 102. The backsheet 136 may be impervious tofluids (e.g., menses, urine, and/or runny feces) and may be manufacturedfrom a thin plastic film, although other flexible liquid imperviousmaterials may also be used. The backsheet 136 may prevent the exudatesabsorbed and contained in the absorbent core from wetting articles whichcontact the diaper 100T and 100P, such as bedsheets, pajamas andundergarments. The backsheet 136 may also comprise a woven or nonwovenmaterial, polymeric films such as thermoplastic films of polyethylene orpolypropylene, and/or a multi-layer or composite materials comprising afilm and a nonwoven material (e.g., having an inner film layer and anouter nonwoven layer). The backsheet may also comprise an elastomericfilm. An example backsheet 140 may be a polyethylene film having athickness of from about 0.012 mm (0.5 mils) to about 0.051 mm (2.0mils). Exemplary polyethylene films are manufactured by ClopayCorporation of Cincinnati, Ohio, under the designation BR-120 and BR-121and by Tredegar Film Products of Terre Haute, Ind., under thedesignation XP-39385. The backsheet 136 may also be embossed and/ormatte-finished to provide a more clothlike appearance. Further, thebacksheet 136 may permit vapors to escape from the absorbent core (i.e.the backsheet is breathable) while still preventing exudates frompassing through the backsheet 136. The size of the backsheet 136 may bedictated by the size of the absorbent core 142 and/or particularconfiguration or size of the diaper 100T and 100P.

Also described above, the taped and pant diapers 100T and 100P mayinclude a topsheet 138. The topsheet 138 may also define all or part ofthe inner surface 132 of the chassis 102. The topsheet 138 may becompliant, soft feeling, and non-irritating to the wearer's skin. It maybe elastically stretchable in one or two directions. Further, thetopsheet 138 may be liquid pervious, permitting liquids (e.g., menses,urine, and/or runny feces) to penetrate through its thickness. Asuitable topsheet 138 may be manufactured from a wide range of materialssuch as woven and nonwoven materials; apertured or hydroformedthermoplastic films; apertured nonwovens, porous foams; reticulatedfoams; reticulated thermoplastic films; and thermoplastic scrims.Suitable woven and nonwoven materials may comprise natural fibers suchas wood or cotton fibers; synthetic fibers such as polyester,polypropylene, or polyethylene fibers; or combinations thereof. If thetopsheet 138 includes fibers, the fibers may be spunbond, carded,wet-laid, meltblown, hydroentangled, or otherwise processed as is knownin the art.

Topsheets 138 may be selected from high loft nonwoven topsheets,apertured film topsheets and apertured nonwoven topsheets. Aperturedfilm topsheets may be pervious to bodily exudates, yet non-absorbent,and have a reduced tendency to allow fluids to pass back through andrewet the wearer's skin. Example apertured films may include thosedescribed in U.S. Pat. Nos. 5,628,097; 5,916,661; 6,545,197; and6,107,539.

As mentioned above, the taped and pant diapers 100P and 100T may alsoinclude an absorbent assembly 140 that is joined to the chassis 102. Asshown in FIGS. 1-3, the absorbent assembly 140 may have a laterallyextending front edge 148 in the front waist region 116 and may have alongitudinally opposing and laterally extending back edge 150 in theback waist region 118. The absorbent assembly may have a longitudinallyextending right side edge 152 and may have a laterally opposing andlongitudinally extending left side edge 154, both absorbent assemblyside edges 152 and 154 may extend longitudinally between the front edge148 and the back edge 150. The absorbent assembly 140 may additionallyinclude one or more absorbent cores 142 or absorbent core layers. Theabsorbent core 142 may be at least partially disposed between thetopsheet 138 and the backsheet 136 and may be formed in various sizesand shapes that are compatible with the diaper 100T, and 100P. Exemplaryabsorbent structures for use as the absorbent core of the presentdisclosure are described in U.S. Pat. Nos. 4,610,678; 4,673,402;4,888,231; and 4,834,735.

Some absorbent core embodiments may comprise fluid storage cores thatcontain reduced amounts of cellulosic airfelt material. For instance,such cores may comprise less than about 40%, 30%, 20%, 10%, 5%, or even1% of cellulosic airfelt material. Such a core may comprises primarilyabsorbent gelling material (AGM) in amounts of at least about 60%, 70%,80%, 85%, 90%, 95%, or even about 100%, where the remainder of the corecomprises a microfiber glue (if applicable). Such cores, microfiberglues, and absorbent gelling materials are described in U.S. Pat. Nos.5,599,335; 5,562,646; 5,669,894; and 6,790,798 as well as U.S. PatentPublication Nos. 2004/0158212 and 2004/0097895.

As previously mentioned, the taped diapers 100T and pant diapers 100Pmay also include elasticized leg cuffs 156 and an elasticized waistband158. It is to be appreciated that the leg cuffs 156 can be and aresometimes also referred to as leg bands, side flaps, barrier cuffs,elastic cuffs or gasketing cuffs. The elasticized leg cuffs 156 may beconfigured in various ways to help reduce the leakage of body exudatesin the leg regions. Example leg cuffs 156 may include those described inU.S. Pat. Nos. 3,860,003; 4,909,803; 4,695,278; 4,795,454; 4,704,115;4,909,803; and U.S. Patent Publication No. 2009/0312730A1.

The elasticized waistband 158 may provide improved fit and containmentand may be that portion or zone of the diaper 100T and 100P that mayelastically expand and contract to dynamically fit a wearer's waist. Theelasticized waistband 158 may extend longitudinally inwardly from thewaist edges 120, 122 of the diaper toward the lateral edges 148, 150 ofthe absorbent core 142. The diaper 100T and 100P may also include twoelasticized waistbands 158, one positioned in the back waist region 118and one positioned in the front wait region 116, although otherembodiments may be constructed with a single elasticized waistband 158.The elasticized waistband 158 may be constructed in a number ofdifferent configurations including those described in U.S. Pat. Nos.4,515,595 and 5,151,092.

The elasticized waistbands 158 may include materials that have been“prestrained” or “mechanically prestrained” (i.e. subjected to somedegree of localized pattern mechanical stretching to permanentlyelongate the material). The materials may be prestrained using deepembossing techniques as are known in the art. In some embodiments, thematerials may be prestrained by directing the material through anincremental mechanical stretching system as described in U.S. Pat. No.5,330,458. The materials are then allowed to return to theirsubstantially untensioned condition, thus forming a zero strain stretchmaterial that is extensible, at least up to the point of initialstretching. Examples of zero strain materials are disclosed in U.S. Pat.Nos. 2,075,189; 3,025,199; 4,107,364; 4,209,563; 4,834,741; and5,151,092.

As shown in FIGS. 1-3, the chassis 102 may have longitudinally extendingand laterally opposing side flaps 160 that are disposed on the interiorsurface 132 of the chassis 102 that faces inwardly toward the wearer andcontacts the wearer. Each side flap may have a proximal edge. The sideflaps may also overlap the absorbent assembly 140, i.e. the proximaledges extend laterally inward of the respective side edges of theabsorbent assembly 152 and 154. In some configurations, the side flapsmay not overlap the absorbent assembly. It is to be appreciated that theside flaps may be formed in various ways, such as for example, byfolding portions of the chassis 102 laterally inward, i.e. toward thelongitudinal axis 124, to form both the respective side flaps and theside edges 128 and 130 of the chassis 102. In another example, the sideflaps may be formed by attaching an additional layer or layers to thechassis at or adjacent to each of the respective side edges and of thechassis. Each of the side flaps may be joined to the interior surface132 of the chassis and/or the absorbent assembly in side flap attachmentzones in the front waist region 116 and in side flap attachment zones inthe back waist region 118. The side flaps may extend to the samelongitudinal extent as the absorbent article or alternatively the sideflaps may have a longitudinal extent that is less than the absorbentarticle.

As previously mentioned, pant and taped diapers may have distinctdifferent features and/or components. And the following provides ageneral discussion of some such features and components with referenceto accompanying figures showing embodiments of taped and pant diapers.

Taped diapers may be manufactured and provided to consumers in aconfiguration wherein the front waist region and the back waist regionare not fastened, pre-fastened, or connected to each other as packaged,prior to being applied to the wearer. As shown in FIG. 4, for example,the taped diaper 100T may be folded about a lateral centerline with theinterior surface 132 of the first waist region 116 in surface to surfacecontact with the interior surface 132 of the second waist region 118without fastening or joining the waist regions together. The back ears104 and 106 and/or the front ears 108 and 110 when present may also befolded laterally inward toward the inner surfaces 132 of the waistregions 116 and 118.

The taped diaper 100T may include various configurations of fasteningelements to enable fastening of the front waist region 116 and the backwaist region 118 together to form a closed waist circumference and legopenings once the diaper is positioned on a wearer. For example, asshown in FIG. 1A, the taped diaper 100T may include first and secondback ears 104 and 106 and first and second front ears 108 and 110,wherein the first and second back ears 104 and 106 are configured toinclude fastening components 162 and 164. Each fastening component 162and 164 may form a portion of or may be permanently bonded, adhered orotherwise joined directly or indirectly to the chassis 102 laterallyinward from the side edge 128 and 130, in one of the front waist region116 or the back waist region 118. Alternatively, the fastening component162 and 164 may form a portion of or may be permanently bonded, adheredor otherwise joined directly or indirectly to the first and second backears 104 and 106 at or adjacent the distal edge of the ear and/or thefirst and second front ears 108 and 110 at or adjacent the distal edgeof the ear. The fastening components may also be permanently bonded orjoined at or adjacent the side edges 128 and 130 of the absorbentarticle in various ways, such as for example, by adhesive bonds, sonicbonds, pressure bonds, thermal bonds or combinations thereof.

The first fastening component 162 and/or the second fastening component164 may include various types of releasably engageable fasteners. Thefirst and second fastening components 162 and/or 164 may also includevarious types of refastenable fastening structures. For example, thefirst and second fastening components 162 and 164 may include mechanicalfasteners, 166, in the form of hook and loop fasteners, hook and hookfasteners, macrofasteners, buttons, snaps, tab and slot fasteners, tapefasteners, adhesive fasteners, cohesive fasteners, magnetic fasteners,hermaphrodidic fasteners, and the like. Some examples of fasteningsystems and/or fastening components 162, 164 are discussed in U.S. Pat.Nos. 3,848,594; 4,662,875; 4,846,815; 4,894,060; 4,946,527; 5,151,092;5,221,274; 6,251,097; 6,669,618; 6,432,098; and U.S. Patent PublicationNos. 2007/0078427 and 2007/0093769.

As previously mentioned, the fastening components 162 and 164 may beadapted to releasably and/or refastenably engage or connect with anotherportion of the diaper 100T. For example, as shown in FIG. 1, the diaper100T may include a connection zone 168, sometimes referred to as alanding zone, in the first waist region 116. As such, when the tapeddiaper 100T is placed on a wearer, the fasteners 162 and 164 are pulledaround the waist of the wearer and connected with the connection zone168 in the first waist region 116 to form a closed waist circumferenceand a pair of laterally opposing leg openings. It is to be appreciatedthat the connection zone may be constructed from a separate substratethat is connected with the chassis 102 of the taped diaper. In someembodiments, the connection zone may be integrally formed as part of thebacksheet 136 of the diaper 100T or may be formed as part of the firstand second ears in one or both of the waist regions, such as describedin U.S. Pat. Nos. 5,735,840 and 5,928,212.

The taped diaper 100T may further include a non-engagement zone disposedon the same surface and in the same waist region as the fasteningcomponents 166. The non-engagement zone may be configured to helpprevent the fastening component 166 from becoming engaged with otherelements of the absorbent article. The non-engagement zone may comprisea film, coating or other material that does not attach to or engage withthe fastening component 166. In certain embodiments the non-engagementzone is in surface to surface contact with the fastening surface of thefastening component when the taped diaper 100T is packaged.

In contrast to taped diapers, pant diapers may be manufactured andprovided to consumers in a configuration wherein the front waist regionand the back waist region are fastened, pre-fastened, or connected toeach other as packaged, prior to being applied to the wearer. As suchpant diapers may have a continuous perimeter waist opening andcontinuous perimeter leg openings designed for infant or adult wearers.As discussed in more detail below, a diaper pant can be preformed byvarious techniques including, but not limited to, joining togetherportions of the diaper using refastenable and/or permanent closuremembers (e.g., seams, heat bonds, pressure welds, adhesives, cohesivebonds, mechanical fasteners, etc.). In addition, pant diapers can bepreformed anywhere along the circumference of the waist region (e.g.,side fastened or connected, front waist fastened or connected, rearwaist fastened or connected).

In some embodiments, pant diapers may be configured with side panelsconnected with the chassis in one or both of the waist regions. Forexample, FIGS. 2 and 5 show a pant diaper 100P including first andsecond side panels 112 and 114 connected with the rear waist region 118.The side panels 112 and 114 may be attached at or adjacent the sideedges 128 and 130 of the chassis 102. The side panels 112 and 114 may besubstantially rectangular in shape or the side panels may be shaped insuch a way as to provide an integral tab for ease of opening andrefastening. The side panels may be also be extensible in at least thelateral direction. The side panels may also be elastically extensible inthe lateral direction. Furthermore, the side panels may be elasticallyextensible in both the longitudinal and lateral directions. The sidepanels may comprise a film, a nonwoven or a combination of film andnonwoven. The side panels may also comprise a plurality of strand-likefilaments and a nonwoven. The strand-like elements may also beelastically extensible in at least the lateral direction.

As previously mentioned and with reference to FIGS. 2 and 5, the firstand second side panels 112 and 114 may connect the first waist region116 with the second waist region 118 of the chassis 102 to form a waistopening 170 and two leg openings 172. For example, proximal end regions174 of the first and second side panels 112 and 114 are connected withthe rear waist region 118 of the chassis 102 and distal end regions 176of the first and second side panels 112 and 114 are connected with thefront waist region 116 of the chassis to the form the pant diaper 100P.

It is to be appreciated that the either or both the distal and proximalregions of one or both the side panels 114 and 116 may be connected withthe chassis in various ways. For example, in some configurations, theside panels are permanently connected with opposing waist regions andcannot be refastened once broken forming the leg and waist openings.Such permanent seams are pre-closed to provide a product that looks likeunderwear and can be applied like underwear, i.e. pulled-on. Disposablepant diapers with permanent seams may require a separate element fordisposal such as a disposal tape disposed on the outer surface of thearticle. Other disposable pant diapers may have non-permanent seams andmay be refastenable allowing the caregiver to open the initial waistopening circumference and leg openings and reclose them to facilitateapplication similar to a traditional tape style diaper. As such, theproximal regions and/or distal regions of the side panels may bepermanently bonded, releasably connected, and/or refastenably connectedwith the chassis 102, with for example, adhesives, cohesives, thermalbonding, ultrasonic bonding, mechanical bonding and mechanical fasteninge.g. hook and loop type fasteners. For example, one or more fastenerelements may be located on or form a portion of the side panels and maybe adapted to refastenably connect with one or more correspondingfastening elements located in the first or second waist regions oralternatively the fastener elements may be adapted to refastenablyconnect with one or more components of the absorbent article includingthe side panels. The diaper pant 100P can also include other featuressuch as elastically extensible side panels that may each include one ormore pieces of material. It should be appreciated that the side panelsmay also be formed as continuous extensions of the first and secondwaist regions of the chassis.

The ability to refasten an initially pre-fastened pant diaper may offerconvenience to the caregiver. In some instances, it may be moreconvenient to apply the absorbent article like a traditional tape stylediaper when away from home or when it is inconvenient to remove theclothing and/or shoes. Because it is difficult to predict when a changewill be necessary and therefore when a particular mode of applicationwill be needed, it is beneficial to have a disposable pant diaper thatis adaptable to being applied either as a traditional tape style diaperor as a disposable pant diaper, pull-on. In addition, an absorbentarticle that can be applied like a traditional tape style diaper or adisposable pant diaper also permits inspection of the interior of theproduct without having to pull the product down. These refastenablestructures may also provide dual functionality enabling the wrapping anddisposal of the used product.

As previously mentioned, the side panels on pant diapers can beconfigured in different ways. Although the side panels 112 and 114 shownin FIGS. 2 and 5 may be of a single unitary piece construction, it is tobe appreciated that the side panels may be formed by connecting earpanels together. In some embodiments, pant diapers may be configuredwith side panels connected with the chassis in both of the waistregions. For example, FIGS. 3 and 6 show a pant diaper 100P wherein thefirst side panel 112 includes a first ear panel 112 a connected with asecond ear panel 112 b, and the second side panel 114 includes a firstear panel 114 a connected with a second ear panel 114 b. The first earpanels 112 a, 114 a each include proximal regions 174 a connected withthe first waist region 116 of the chassis 102. And second ear panels 112b, 114 b each include proximal regions 174 b connected with the secondwaist region 118 of the chassis 102. A distal region 176 a of the firstear panel 112 a and a distal region 176 b of the second ear panel 112 bmay be connected with each other along a first side seam 178 to form thefirst side panel 112. And a distal region 176 a of the first ear panel114 a and a distal region 176 b of the second ear panel 114 b may beconnected with each other along a second side seam 180 to form thesecond side panel 114.

It is to be appreciated that the proximal regions of the ear panels ofFIGS. 3 and 6 may be connected with the chassis in various ways, and thedistal regions of the ear panels may be connected with each other invarious ways. For example, the proximal regions and/or distal regions ofthe side panels may be permanently bonded, releasably connected, and/orrefastenably connected with the chassis and/or each other, with forexample, adhesives, cohesives, thermal bonding, ultrasonic bonding,mechanical bonding and mechanical fastening e.g. hook and loop typefasteners. For example, one or more fastener elements may be located onthe side panels and may be adapted to refastenably connect with one ormore corresponding fastening elements located in the first or secondwaist regions or alternatively the fastener elements may be adapted torefastenably connect with one or more components of the absorbentarticle including the side panels. The diaper pants can also includeother features such as elastically extensible side panels that may eachinclude one or more pieces of material.

It should also be appreciated that the side panels in one waist regionmay have the same lateral extent from the side edge of the chassis tothe distal edge of the side panel as the longitudinally opposed sidepanels in the opposite waist region or alternatively the side panelsdisposed in a first waist region may have different lateral extent asmeasured from the side edge of the chassis to the distal edge of theside panel than the side panels disposed in a second waist region.

As such, for a pant diaper including side seams, a first portion of thepant diaper 100P adjacent the first side edge 128 in the front waistregion 116 and a second portion of the pant diaper adjacent the firstside edge 128 in the back waist region 118 may be connected to form afirst permanent side edge seam 178. And a third portion of the pantdiaper 100P adjacent the second side edge 130 in the front waist region116 and a fourth portion of the pant diaper adjacent the second sideedge 130 in the back waist region 118 may be connected to form a secondpermanent side edge seam 180. The connection of the side edge seams 178and 180 define the initial waist opening 170 circumference and a pair ofleg openings 172. In another configuration, a pant diaper 100P mayinclude a first mating fastening component having a fastening surfaceand an opposing attachment surface wherein the attachment surface isjoined directly to one of the interior or exterior surface of the pantdiaper in a first waist region. The pant diaper may further comprise asecond mating fastening component having a fastening surface and anopposing attachment surface wherein the attachment surface may be joineddirectly to the same surface of the pant diaper as the first fasteningcomponent. The second mating fastening component may be joined to or mayform a portion of the surface to which the attachment surface of thefirst mating fastening component is joined.

In yet another configuration, the pant diaper may include a frangibleseparation zone that may be disposed laterally inward of the side edgeseams 178 and 180 that allows the initial waist opening circumference170 and leg openings 172 of the pant 100P to be opened for removal or toenable application as a traditional tape style diaper. As discussedabove, the pant diaper may further include a first fastening componentand a second fastening component disposed in one of the front or backwaist regions 116 and 118. And each of the fastening components may bedisposed on the same surface of the pant diaper 100P, e.g., the exteriorsurface 134. The fastening components may be capable of being fastenedin a traditional tape style diaper fashion or fastened to reform asecondary waist opening circumference and leg openings after the initialwaist opening circumference and leg openings have been broken. Inaddition, the fastening components can be used to aid disposal of asoiled pant.

As previously mentioned, the bonds of the side edge seams 178 and 180may be permanent and can be formed in various ways appropriate for thespecific materials employed. Thus, example bond types may includediscrete bonds such as sonic sealed bonds, heat sealed bonds, highpressure bonds, radio frequency bonds, adhesive or cohesive bonds, sewedbonds, autogeneous bonds, and combinations thereof. In accordance withone aspect of the disclosure, the permanent side edge seams 178 and 180may be joined by a predetermined pattern of heat/pressure or ultrasonicwelds which withstands the forces and stresses exacted onto the sideedge seam 51 during application and wear of the pant 20. The permanentside edge seams 178, 180 may be formed as disclosed in U.S. Pat. Nos.5,779,831; 5,772,825; 5,607,537; 5,622,589; 5,662,638; 6,042,673; and6,726,792.

Because the pant diaper 100P may be configured with permanent side edgeseams 178 and 180, both permanent side edge seams may be pre-closed,meaning that the side edge seams are closed prior to removal of thediaper pant from its package, and therefore prior to being donned on thewearer. The pre-closed permanent side edge seams 178 and 180 may form aninitial waist opening circumference and leg circumferences. The initialwaist opening circumference and leg circumferences may be opened atpredetermined frangible separation zones. The permanent side edge seamscannot be reclosed to form the secondary waist opening circumference andleg openings.

Additionally, various diaper pant configurations are disclosed in U.S.Pat. Nos. 5,246,433; 5,569,234; 6,120,487; 6,120,489; 4,940,464;5,092,861; 5,897,545; 5,957,908; and U.S. Patent Publication Nos.2003/0233082; 2005/0234419; 2003/0088220; 2005/0130821; 2003/0233082;2005/0215971; 2005/0215970; 2007/0078427; 2007/0093769; 2007/0074381;2007/0078426; and 2008/0107861.

As previously discussed, converting apparatuses and methods formanufacturing taped and pant diapers according to the present disclosureare adapted to operate in at least a first configuration and a secondconfiguration. And the converting apparatus includes transformationmechanisms adapted to produce a series of transformations. In a firstconfiguration, a first plurality of the transformation mechanisms arearranged to produce a plurality of taped diapers, wherein the firstplurality of the transformation mechanisms produce a first number oftransformations. In a second configuration, a second plurality of thetransformation mechanisms are arranged to produce a plurality of pantdiapers, wherein the second plurality of the transformation mechanismsproduce a second number of transformations. As discussed in more detailbelow with reference to FIGS. 8-10, the converting apparatus may beconfigured with relatively high flexibility in changing between thefirst and second configurations, because a relatively large percentageof transformations remain the same in both configurations.

FIG. 8 shows a schematic view of a converting apparatus 300 in a firstconfiguration adapted to manufacture taped diapers 100T. The method ofoperation of the converting apparatus 300 may described with referenceto the various components of taped diapers 100T described above andshown in FIGS. 1, 1A, and 4. It is to be appreciated transformationsshown and described herein can be carried out in various differentorders than that which is depicted and described herein. As shown inFIG. 8, a topsheet assembly process is completed at step 1001, and acore assembly process is completed at step 1002. The core assembly iscombined with the advancing topsheet substrate at transformation 2001.In addition, a leg cuff assembly process is completed at step 1003 andis combined with the advancing topsheet at transformation 2002 formingthe topsheet substrate. At the same time, a backsheet assembly processmay be completed at step 1004, and a leg elastic assembly process iscompleted at step 1005. The leg elastics are combined with the advancingbacksheet substrate at transformation 2003. In addition, a back earassembly process is completed at step 1006T; a front ear assemblyprocess is completed at step 1007T; and a landing zone assembly processis completed at step 1008T. The back ears, front ears, and landing zoneare combined with the advancing backsheet substrate at transformations2004T, 2005T, and 2006T, respectively forming the backsheet substrate.Next, the advancing backsheet substrate and topsheet substrate arecombined at transformation 2007 to create a continuous length of tapeddiapers. And the continuous length of taped diapers is subjected to afinal forming process at step 1009.

It is to be appreciated that one or more transformations may occurduring each process step shown in FIG. 8. For example, as shown in FIG.8A the topsheet assembly process 1001 may include 2 transformations,such as for example: (1) Substrate CD positioning; and (2) Adhesiveapplication. The core forming process 1002 may include 16transformations, such as for example: (1) Disintegration/fiberization;(2) AGM/fiber mixing; (3) Bottom core wrap (BCW) CD positioning; (4)Adhesive application; (5) Core formation/deposition; (6) Top core wrap(TCW) CD positioning; (7) Adhesive application; (8) BCW, core and TCWcombining; (9) Adhesive application; (10) Acquisition coredeposition/formation; (11) Acquisition layer cutting; (12) Acquisitionlayer spacing; (13) Core and acquisition layer combining; (14) Absorbentcore calendaring; (15) Absorbent core cutting; and (16) Absorbent corespacing. And the leg cuff assembly process 1003 may include 8transformations, such as for example: (1) Cuff material slitting; (2)Cuff CD Positioning; (3) Elastic unwind/tensioning; (4) Adhesiveapplication; (5) Cuff and elastic combining; (6) Cuff hem folding; (7)Cuff hem bonding; and (8) Adhesive application.

In other examples, such as shown in FIG. 8B, the backsheet assemblyprocess 1004 may include 6 transformations, such as for example: (1)Backsheet nonwoven CD positioning; (2) Glue application; (3) Backsheetfilm CD positioning; (4) Film and nonwoven combining; (5) Backsheetlaminate CD positioning; and (6) Adhesive application. The leg elasticassembly 1005 may include 2 transformations, such as for example: (1)Elastic unwind/tensioning; and (2) Adhesive application. The back earassembly 1006T may include 12 transformations, such as for example: (1)Release tape folding; (2) Fastening tape CD positioning; (3) Fasteningtape shaping; (4) Release, hook and fastening tape combining; (5) Backear CD positioning; (6) Back ear and tape combining; (7) Back ear withtape bonding; (8) Back ear with tape folding; (9) Back ear slitting;(10) Back ear CD positioning; (11) Back ear shaping; and (12) Back earMD positioning. The front ear assembly 1007T may include 7transformations, such as for example: (1) CD positioning; (2) EarShaping; (3) CD positioning; (4) MD positioning; (5) Adhesiveapplication; (6) Ear Cutting; and (7) Ear Spacing. And the landing zoneassembly 1008T may include 4 transformations, such as for example: (1)CD positioning; (2) Adhesive application; (3) Cutting; and (4) Spacing.

Referring back to FIG. 8, the final forming process 1009 may include 4transformations. For example, the final forming process 1009 for tapeddiapers may include a front and back ear folding transformation 2008T.In the front and/or back ear folding transformation 2008T, thecontinuous length of taped diapers may be subjected to a process whereinfolding bars or other type of mechanism folds the front ears 108 and 110and/or back ears 104 and 106 laterally inward toward each other and ontothe inner surfaces 132 of the taped diapers 100T, such as shown in FIG.4. The final forming process 1009 may also include a final knife cuttransformation 2009 wherein the continuous length of taped diapers arecut into separate and discrete taped diapers 100T. The discrete diapersmay also be subjected to a folding transformation 2010 wherein eachdiaper is folded along a laterally extending fold line, such as shown inFIG. 4. Finally, the taped diapers may be subjected to stackingtransformation 2011 wherein folded taped diapers are stacked andprepared for packing.

As previously mentioned, the core assembly process 1002 may include anumber of different transformations. It is to be appreciated that thesetransformations may be dependent on the actual composition of theabsorbent materials forming the absorbent core. For example,heterogeneous absorbent cores comprising a blend a fibrous material anda particulate material may be formed by a blending transformation thatblends, mixes or combines the fibrous component and a particulatecomponent to form a heterogeneous absorbent structure. Examples of suchheterogeneous structures may include blends of cellulosic fibers andabsorbent gelling material wherein the cellulosic material may bepresent in a percentage from about 5% to about 95% and the absorbentgelling material present a percentage from about 95% to about 5%respectively. In some embodiments, the heterogeneous structure maycomprise a blend of adhesive fibers and absorbent gelling materialwherein the adhesive fibers are present in a percentage from about 2% toabout 70% and the absorbent gelling material is present in a percentagefrom about 98% to about 30% respectively. In such embodiments, thecellulosic fibrous material may be supplied to the production line inbale form and/or in drylap form. Both of these forms may require afiberization step to separate the fibers into individual fibers or smallgroupings of fibers to facilitate blending/mixing of the fibers withother materials. The absorbent gelling material may be supplied to theproduction line in particulate form and no further manipulation isrequired prior to formation of the heterogeneous structure. Theindividual fibers or small groupings of fibers may be mixed with theabsorbent gelling material to form a heterogeneous mixture. The mixturemay also be deposited onto a vacuum conveyance such as a vacuum belt ora vacuum drum to form either a continuous web of absorbent material oralternatively a plurality of discrete absorbent cores. The formation ofthe heterogeneous fiber AGM absorbent core material therefore mayinclude at least three distinct transformations as detailed hereinabove; fiberization, mixing and deposition.

It is to be appreciated that formation of an absorbent core from amaterial that is supplied to the production line in roll form is alsopossible. Examples of such web form absorbent materials include tissuelaminates (laminates of tissue and absorbent gelling material), nonwovenlaminates (laminates of nonwoven and absorbent gelling material),absorbent foams, high basis weight absorbent tissues, absorbent wadding,thermally bonded cellulosic fiber and absorbent gelling materialcomposites, chemically bonded cellulosic fiber and absorbent gellingmaterial composites and the like. The material may simply be unwound andsubsequently severed in the cross machine direction at the desiredmachine direction length. The material may also be severed in themachine direction, either linearly or in a shaped pattern such as arepeating nested pattern. The cross machine direction cutting and/or themachine direction cutting and/or shaping may also form specifictransformation steps as described herein.

The following provides additional explanation of “unwinding,” which maybe a part of various process assemblies used in the converting line 300shown in FIGS. 8A and 8B but is not considered to be a transformation.Many materials are supplied to the production line in the form of acontinuous web disposed in roll form. Examples of such web materialsinclude films, including polymeric films, elastomeric films, microporousfilms, monolithic films and the like as well as woven and nonwovenmaterials, including carded, meltblown and spunbond materials comprisingpolymeric fibers such as polyethylene, polypropylene and the like aswell as fiber materials such as rayon. The materials may be delivered tothe production line by means of a material unwind. The material unwindmay comprise a splicing unit which splices the end of one rollcomprising a continuous web material to the beginning of a subsequentroll of continuous web material. This process may be repeated such thatthe process may run uninterrupted. The splicing feature may form atransformation, i.e. splicing (e.g. bonding). If the splicing stepincludes a cutting step, the cutting step may form a separatetransformation.

With further regard to unwinding, some materials may be supplied to theproduction line in the form of composite web, i.e. a web comprising twoor more distinct layers or structures, disposed in roll form. Examplesof such web materials include composites of films and nonwovens,including polymeric films, elastomeric films, microporous films,monolithic films and the like combined with woven and/or nonwovenmaterials, such as carded and/or spunbond materials comprising polymericfibers such as polyethylene, polypropylene and the like. This type ofunwind may also comprise a splicing feature. The material splicingfeature forms transformations, i.e. splicing (e.g. bonding). If thesplicing step includes a cutting step, the cutting step may form aseparate transformation.

In addition, materials such as elastics may be supplied to a productionline in the form of a film or a continuous strand disposed on a roll orspool. Examples of such strand materials include: lycra elastics,natural rubber elastics, threads, strings and the like. The materialsmay be delivered to the production line by means of a material unwind.The material unwind may comprise guides to properly space the strandsand provide proper orientation of the strand relative to the absorbentarticle. The unwind may also comprise a tensioning device, meteringcontrol, which adds tension to the film or strand which in the case ofan elastic extends the elastic thereby controlling the elasticcontraction force once applied to the article. In some instances, theproduction line is stopped to splice in new rolls of strand materials.These materials, in particular, strand materials may have an extremelylong run time and therefore the stoppage required for changeover mayhave a minimal impact on the efficiency of the converting process. Amaterial unwind comprising a tensioning device may form atransformation.

The following provides additional explanation of the transformationsreferred to as “spacing,” which may be a part of various processassemblies used in the converting line 300 shown in FIGS. 8A and 8B.Taped and pant diapers may include multiple components which may havedifferent longitudinal, machine direction, extents as well as differentlateral, cross machine direction, extents. For materials that havedifferent machine direction extents certain elements may be spaced apartsuch that these elements are properly disposed relative to andcorrespond with other elements of the absorbent article. There arevarious processes by which these spaces may be created. One such processcomprises a first conveyance, such as a vacuum conveyor, having asurface speed and a second conveyance, such as a vacuum conveyor, havinga surface speed the surface speed of the second conveyance being greaterthan the surface speed of the first conveyance whereby transferring adiscrete element from the first conveyance to the second conveyanceincreases the distance between the discrete elements. In such anembodiment the first and second conveyances may form a transformationsince both are required to space the element. In another embodiment, theprocess may include a continuous web wherein the web has a surface speedand a first conveyance, such as a vacuum drum, having a surface speedthe surface speed of the first conveyance being greater than the surfacespeed of the web wherein the web is severed in a cross machine directiontransferring a discrete element from the web onto the first conveyancewhereby the discrete element is subsequently transported at the higherspeed to space the discrete elements appropriately relative to theremainder of the absorbent article. In such a configuration the firstconveyance may form a transformation. Additionally severing the web inthe cross machine direction may form a separate transformation asdescribed herein.

The following provides additional explanation of the transformationsreferred to as “adhesive application,” and “bonding,” which may be apart of various process assemblies used in the converting line 300 shownin FIGS. 8A and 8B. Adhesive bonding may be employed to create a bondwithin a specific element for example bonding two layers of a foldedelement together or alternatively to attach two separate elements of anabsorbent article together. There are several types of adhesives thatcan be used to form the bonds including hotmelt adhesives, cohesives,A-B adhesives and the like. An adhesive bond may be disposed in apattern that may be substantially continuous in one or both of thelateral or longitudinal directions across the absorbent article or itmay form an intermittent pattern in one or both of those directions. Theadhesive bond may also be in the form of one or more beads, one or morespirals, one or more repeating, e.g. zigzag, or random, e.g. spray,patterns, one or more slot coatings or may be formed by printing of theadhesive. Non-limiting examples of adhesive bonds that may be used inabsorbent articles include: backsheet film to backsheet nonwoven bond,backsheet to absorbent assembly bond, absorbent core to core cover bond,storage core to acquisition core bond, absorbent assembly to topsheetbond, backsheet to topsheet bond, backsheet to barrier leg cuff bond,barrier leg cuff to topsheet bond, barrier leg elastic attachment bond,outer leg elastic attachment bond, side panel film to side panelnonwoven bond, waistband to absorbent article bond, side panel tochassis bond, landing zone to backsheet bond, and fastening component toabsorbent article bond. Each of these examples may represent a separatetransformation within the production line. Generally speaking theprocess to apply an adhesive bond comprises a reservoir to maintain asupply of the adhesive, a dispensing device such as a pump, a transportdevice, for example a hose, and an applicator, i.e. nozzle. In certaintransformations comprising multiple adhesive bonds for example theprocess equipment may comprise a reservoir, pump, hose and anapplication head with one or more applicator nozzles disposed thereon.Alternatively, the transformation may comprise a reservoir, pump, hoseand more than one application head with one or more applicator nozzlesdisposed thereon. It is also anticipated that one reservoir may supplymultiple transformations for example of the same adhesive is used fortwo separate bonding applications the same reservoir may be used to holdthe supply of adhesive. Adhesive bonding may comprise one or more of thefollowing transformations, adhesive application, material combining,nipping and/or calendaring.

It is to be appreciated that many forms of bonding may be used to createa bond within a specific element for example bonding two layers of afolded element together or alternatively to attach two or more elementsof an absorbent article together. For example, thermal bonding may beused to create such bonds. There are several specific types of thermalbonds including thermal bonds resulting from direct application of heat,thermal bonds generated by sonic waves for example, ultrasonic bonds andpressure bonds which generate heat by means of pressure. A thermal bondmay be present in one position on the absorbent article or may bepresent in laterally or longitudinally opposing pairs. In embodimentswherein laterally or longitudinally opposing pairs of thermal bonds arepresent the pairs of bonds and the equipment used to create the pairs ofbonds may form a transformation. In embodiments comprising multiplethermal bonds for example a continuous pattern of thermal bondsextending the length and/or the width of the absorbent article theequipment used to create such a continuous pattern of thermal bonds mayform a transformation.

Although not specifically recited in the process steps shown in FIGS.8-8B, it is to be appreciated that some process steps may include atransformation referred as activation. The activation of a web ofmaterial or a composite web of several materials can provide anactivated web material that can be laterally extended beyond itsoriginal dimension with the application of relatively less force thanthat required to extend the same material to the same extent whenunactivated. In certain embodiments, the result of activation is thecreation of ridges and valleys in one or more layers forming theactivated web material. Application of opposing divergent forcesdirected generally perpendicular to the ridges and valleys typicallyresults in the extension of such a formed web material along an axisbetween the opposing forces.

The activation approaches described herein may be achieved by using aset, two or more, intermeshing opposing rolls comprising a staggeredorientation of teeth such that when a material such a single web orcomposite web of material passes through the intermeshing rolls, atleast a portion of the material is partially deformed to create thedesired activation pattern in the web. The teeth of one or more of therolls may be continuous around the circumference of the roll while theteeth on one or more of the intermeshing opposing rolls may bediscontinuous forming intermittent activation (e.g. a structuredelastic-like formed web) or a pitched continuous activation (e.g.continuously activated in the opposing waist regions and not the crotchregion). One such process for activating materials to provideextensibility is described in U.S. Pat. No. 5,518,801 issued on 21 May1996 in the name of Chappell et al. The depth to which the teethintermesh, i.e. depth of engagement, will determine to what degree theweb is incrementally stretched and/or plastically deformed and thereforethe degree of extensibility imparted to the web. In some embodiments,the absorbent article can be activated in a portion of the backsheet,the waist region, the waistband, the side panels and or the leg cuffsfor example, to provide additional extensibility.

In some embodiments, a portion of the absorbent article may becontinuously activated meaning that the teeth of two or more of therolls may be continuous around the circumference of the roll whileforming continuous activation (e.g., ring-rolled and thus renderedhighly extensible as described in U.S. Pat. No. 5,366,782 (issued Nov.22, 1994 to Curro, et al)). Specifically, a ring-rolling apparatus whichcomprises opposing rolls having intermeshing teeth that incrementallystretch and thereby plastically deform the chassis (or a portionthereof) thereby rendering the chassis extensible in the ring-rolledregions. In some embodiments, the side panels that form a portion of atleast one of the front and/or back waist regions may be activated byring rolling while other regions of the absorbent article remainunactivated or are activated to form a structured elastic-like formedweb material.

The converting methods and apparatuses herein may include various typesof mechanisms to perform the folding transformation 2010 shown in FIG.8, as well as the folding transformations 2010 discussed below withreference to FIGS. 9 and 10. For example, FIGS. 8-10 show an arrangementthat includes a folding apparatus 302 similar to those described in U.S.Patent Publication Nos. 2009/0094941A1 and 2009/0098995A1. The foldingtransformation herein may also utilize the folding methods andapparatuses described in U.S. patent application Ser. No. 13/051,210entitled “Apparatuses and Methods for Folding an Absorbent Article,” andfiled on Mar. 18, 2011.

The method of operation of the folding apparatus 302 may be describedwith reference to the figures herein and in the context of a method forfolding articles, such as taped diapers or pant diapers. The followingprovides various term explanations that may be useful in understandingthe present discussion of the folding apparatus 302. “Leading endportion” means that portion of an absorbent article prior to bi-foldingthat is disposed forward of the fold line in the machine direction.“Trailing end portion” refers to that portion of an absorbent articleprior to bi-folding that is disposed after the fold line in the machinedirection. “Fold line” means the portion of an article about which thearticle is intended to be bi-folded. The fold line typically extendsfrom one longitudinal edge to the other longitudinal edge in the lateraldirection. In certain embodiments, the fold line may correspond to thelateral centerline of the article. “Bi-fold” means the leading edgeportion and the trailing edge portion of an article on a production lineare brought together in a face-to-face configuration along a fold lineas the article moves in the machine direction of travel. “Holding anarticle to the surface of a roll” means employing a holding force to oneor more portions of an article in order to join the article at leasttemporarily to the surface of a roll such that the article is inhibitedfrom traveling in a direction substantially orthogonal to the surface ofthe roll without reducing or removing the holding force and/or employinga peel-force. This definition is equally applicable to conveyors, e.g.,the bi-fold conveyor assembly described herein below. “Peel force” meansthe force applied to an object in a direction that is substantiallyperpendicular to the plane of the surface in which the object lies or onwhich the object rests. A force applied in a direction within 45° of theperpendicular direction may be considered a peel force. “Shear force”means the force applied to an object in a direction that issubstantially parallel to the plane of the surface in which the objectlies or on which the object rests. A force applied in a direction within45° of the parallel direction may be considered a shear force.

As shown in FIGS. 8-10, the articles (i.e. taped and pant diapers 100Tand 100P) advance in a machine direction and are to be folded along across directional fold line. Each article includes a leading end portion200 that may correspond with the front waist region 116 and a trailingend portion 202 that may correspond with the rear waist region 118.After the final knife cut 2009, the articles are received onto atransfer roll 304, and are subsequently received onto a rotating foldingdrum 306. It is to be appreciated that some embodiments may not includea transfer roll. For example, in some embodiments, a continuous lengthof the articles may be received on the folding drum and cut intodiscrete articles directly thereon. As shown in FIGS. 8-10, the diapers100T and 100P may be oriented on the outer surface of the folding drum306 such that the garment facing surface 134, such as defined by thebacksheet 136, is engaged with the outer surface of the folding drum.The folding drum 306 is rotated to move the outer surface at a firstsurface speed and transport the diaper 100T and 100P in the machinedirection. A wearer facing surface 132, such as defined by the topsheet138, of the leading end portion 200 of the diaper 100T and 100P engagesan outer surface of a peel roll 308 traveling at the first speed. Theleading end portion 200 is transferred from the folding drum 306 to thepeel roll 308.

With the leading end portion of the diaper 100T and 100P engaged withthe peel roll 308, the trailing end portion 202 of the diaper 100T and100P remains on the rotating folding drum 306. As the folding drum 306continues to rotate, clamps from the folding drum may operate to holddiaper 100T and 100P onto the folding drum 306 and the clamped portionof the diaper 100T and 100P continues to move with the folding drumouter surface. When the clamps reach a particular position relative tothe peel roll 308, the clamps may exert a force such as, for example, ashear force on the leading end portion 200. The shear force exerted onthe leading end portion 200 may be in a direction that is substantiallydifferent from or even opposite the direction of travel of the outersurface of the peel roll 308. Thus, the leading end portion 200 maybegin to slow down and/or even stop moving. As the leading portion 200decelerates and/or stops moving, the leading end portion 200 of thediaper 100T and 100P is transferred from the peel roll 308 to a vacuumconveyor 310 including a movable surface. And the movable surface of thevacuum conveyor is accelerated to a surface speed equal to orsubstantially equal to the surface speed of the folding drum. Next, thegarment facing surface 132 of the leading end portion 200 of the diaper100T and 100P is transferred along the vacuum conveyor and the leadingend portion is brought into surface to surface contact with the trailingend portion 202 of the diaper 100T and 100P on the folding drum 306.

It is to be appreciated that the folding apparatus can be configured inaccordance with and may include various other features described in U.S.Patent Publication Nos. 2009/0094941A1 and 2009/0098995A1; as well asU.S. patent application Ser. No. 13/051,210, entitled “Apparatuses andMethods for Folding an Absorbent Article,” and filed on Mar. 18, 2011.

The converting apparatus 300 is shown in FIG. 8 in a first configurationadapted to manufacture taped diapers 100T. As previously mentioned, theconverting apparatus 300 can be placed in a second configuration whereinthe transformation mechanisms are arranged to produce a plurality ofpant diapers 100P. As such, the second plurality of transformationmechanisms produce a second number of transformations. For example, theconverting apparatus 300 is shown in FIG. 9 in a second configurationadapted to produce pant diapers 100P, such as shown and described abovewith respect to FIGS. 2, 5, and 7. As discussed in more detail belowwith respect to FIGS. 8 and 9, a relatively large percentage oftransformations remain the same in both configurations.

As mentioned above with respect to FIG. 8, it is to be appreciatedtransformations shown and described in FIG. 9 can be carried out invarious different orders than that which is depicted and describedherein. As shown in FIG. 9, when the converting apparatus 300 is placedin the second configuration for producing pant diapers 100P, thetopsheet assembly process 1001, core assembly 1002, and leg cuffassembly and associated transformations 2001 and 2002 may be the same asdiscussed above with reference to the taped diaper configuration shownin FIG. 8. In addition, backsheet assembly 1004, leg elastic assembly1005 and associated transformations 2003 and 2007 shown in FIG. 9 may bethe same as discussed above with reference to FIG. 8. As such, thetransformations associated with the process assemblies 1001, 1002, 1003,1004 and 1005 discussed above with reference FIGS. 8A and 8B may also bethe same as transformations associated with the process assemblies 1001,1002, 1003, 1004 and 1005 shown in the pant diaper configuration of FIG.9.

Although many of the processes and associated transformations may remainunchanged between the taped diaper configuration shown in FIG. 8 and thepant diaper configuration shown in FIG. 9, there are some differences.For example, in FIG. 9, the front ear assembly 1007T and landing zoneassembly 1008T as well as associated transformations 2005T and 2006T areshown in dashed lines to indicate these assemblies and transformationsmay not be used in the pant diaper configuration. In some embodiments ofthe converting apparatus 300, the transformation mechanisms associatedwith 1007T, 1008T, 2005T, and 2006T need not be physically removed fromthe converting apparatus, but rather, simply disabled, “turned-off” orbypassed when the converting mechanism is placed in the pantconfiguration. It is to be appreciated that in some embodiments, thelanding zone assembly 1008T and associated transformation 2006T may beutilized in some pant manufacturing configurations, such as for example,when manufacturing pant diapers 100P having refastenable side panels.

As shown in FIG. 9, the converting apparatus in the second, pant diaper,configuration may include a side panel assembly process 1006P to createside panels 112 and 114, such as shown in FIG. 2. The panels 112 and 114may also be combined with the backsheet substrate at transformation2004P. It is to be appreciated that the side panel assembly process1006P may also include various transformations. For example, the sidepanel assembly process 1006P may include the identical transformationsas discussed above with reference to the back ear assembly process 1006Tshown in FIGS. 8 and 8B.

As shown in FIGS. 8 and 9, the final forming process 1009 also mayinclude some different transformations depending on whether theconverting apparatus is in the first, taped diaper, configuration or thesecond, pant diaper, configuration. For example, the ear foldingtransformation 2008T shown in FIG. 8 is removed or disabled when theconverting apparatus 300 is placed in the pant configuration shown inFIG. 9. As such, when the pant diapers 100P in FIG. 9 advance past thefinal knife transformation 2009, the side panels 112 and 114 may beextended laterally outward from the longitudinal side edges 128 and 130of the chassis 102, such as shown in FIG. 2. In addition, as shown inFIG. 9, the pant diapers 100P are subject to the same foldingtransformation 2010 as described with reference to the taped diaperconfiguration in FIG. 8. As such, the converting apparatus 300 mayutilize the same folding apparatus 302, such as described above, whetheroperating in the taped diaper configuration or the pant diaperconfiguration. However, when the pant diapers 100P are folded 2010, theside panels 112 and 114 remain in laterally extended positions.

As shown in FIG. 9, the folded pant diapers 100P are subjected toadditional transformations not applied to the taped diapers 100T. Inparticular, the folded pant diapers 100P are subjected to a side panelconnection transformation 2012 and may be subjected to a side paneltucking transformation 2013 before advancing to the stackingtransformation 2011.

When the folded pant diapers 100P advance from the foldingtransformation 2010 and through the side panel connection transformation2012, the distal end regions 176 of the laterally extending side panels112 and 114 are connected with another portion of the pant diaper 100P.For example, the proximal end regions 174 of the side panels 112 and 114such as shown in FIG. 2 may be connected with the rear waist region 118at transformation 2004P discussed above. As such, the side panelconnection transformation 2012 of FIG. 9 may be configured to connectthe distal end regions 176 of the side panels 112 and 114 with the frontwaist region 116 of the diaper pant 100P, such as shown in FIG. 5.

It is to be appreciated that various types of transformation mechanismsmay be used to carry out the side panel connection 2012. For example, atwisted conveyor arrangement, such as shown in FIG. 11 may used totransport the pant diapers 100P in the machine direction while at thesame time bend and fold the side panels 112 and 114 to connect thedistal end regions with the front waist region 116 of the chassis 102.As shown FIG. 11, the chassis 100P of the folded pant diapers 100T maybe transported in the machine direction away from the folding drum 306by an upper vacuum conveyor 400 engaged with the rear waist region 118of the chassis 102 and a lower vacuum conveyor 402 engaged with thefront waist region of the 116 of the chassis. First and second twistedvacuum conveyor 404 and 406 may be laterally disposed on opposing sidesof the upper and lower vacuum conveyors 400 and 402. In particular, thefirst and second twisted vacuum conveyors may include a movable surface,such as an endless belt, that twists along the machine direction, MD. Assuch, the first twisted vacuum conveyor may apply a vacuum force to holdthe first side panel 112, and the second twisted vacuum conveyor mayapply a vacuum force to hold the second side panel 114 as the pantdiaper 100P advances in the machine direction. Thus, as the pant diaper100P advances, the distal end regions 176 of the side panels 112 and 114are folded over and placed in contact with the front waist region 116.The distal end regions 176 of the side panels 112 and 114 may also beconnected with front waist region 116. As discussed above, the sidepanels may be refastenably, releasably, or permanently connected withthe front waist region in various ways, such as with heat, cohesives,mechanical fasteners, adhesives, and the like.

As shown in FIG. 9, the pant diapers 100P may advance from the sidepanel connection transformation 2012 to the side panel tuckingtransformation 2013 before advancing to the stacking transformation2011. The converting methods and apparatuses herein may include varioustypes of mechanisms to perform the side panel tucking transformation2012 shown in FIG. 9, as well as the side panel tucking transformation2012 discussed below with reference to FIG. 10. For example, the sidepanel tucking transformation 2012 may utilize the tucking methods andapparatuses described in U.S. patent application Ser. No. 13/051,241,entitled “Methods and Apparatuses for Tucking Side Panels of AbsorbentArticles,” and filed on Mar. 18, 2011; and U.S. patent application Ser.No. 13/051,231, entitled “Methods and Apparatuses for Tucking SidePanels of Absorbent Articles,” and filed on Mar. 18, 2011; as well asdescribed in U.S. Pat. Nos. 6,723,035 and 6,776,316.

FIG. 7 shows the diaper pant 100P with opposing side panels 112 and 114tucked into the chassis 102. As shown in FIG. 7, portions of each sidepanel 112 and 114 are inserted into the chassis 102 of the diaper pant100P such that portions of the side panels are disposed between theinterior surface 132 of the front waist region 116 and the rear waistregion 118. In addition, the insertion of the side panels 112 and 114into the chassis 102 defines first longitudinal fold lines 250 along thefirst waist region 116 and second longitudinal fold lines 252 along thesecond waist region 118.

FIGS. 12-15 show an example side panel tucking apparatus 500 that may beused to tuck the side panels 112 and 114 into the chassis 102. Theapparatus can include 500 a first conveyor 502, a second conveyor 204.Each conveyor 502 and 504 may include a movable surface 506 that may bein the form of a belt wrapped around rollers and configured in anendless loop. One or more of the belts may also be configured as amovable foraminous vacuum conveyor belt that exerts vacuum forces on thechassis 102 to receive, hold, and/or transfer the diaper pant 100P. Itis to be appreciated that the each conveyor may include more thanconveyor, such as for example, multiple conveyors arranged in seriesalong the machine direction and/or arranged in parallel along the crossdirection. In addition, one or more conveyors can be configured as arotating drum or vacuum drum. The conveyors 202, 204 and 205 advancediaper pants 100P in a machine direction, MD, through a tucking zonerepresented generally by the side panel tucking transformation 2012 inFIGS. 9 and 10, wherein a side panel tucker pushes the side panels 112and 114 into the chassis 102.

FIG. 12 shows a cross-sectional view of the diaper pant 100P and firstand second conveyors 502 and 504. As shown in FIG. 5, the belt 506 ofthe first vacuum conveyor 502 includes a vacuum zone 514 that exerts adownward vacuum force on the outer surface 134 of the first waist region116 of the chassis 102. And the belt 506 of the second vacuum conveyor504 includes a vacuum zone 514 that exerts an upward vacuum force on theouter surface 134 of the second waist region 118 of the chassis 102. Assuch, the opposing forces exerted by the vacuum zones 514 on chassis 102hold the inner surfaces 132 of the first and second waist regions 116,118 apart. In addition, the side panels 112 and 114 are shown in FIG. 12in a relatively elongated and untucked configuration.

As shown in FIG. 12, the vacuum zones 514 of the first and secondconveyors 502 and 504 each define a lateral or cross directional, CD,width that may be less than the lateral width defined by the opposinglongitudinal edges 128 and 130 of the chassis 102. In addition, thelateral or cross directional, CD, width of the vacuum zones 514 may alsobe less than the lateral width defined by the opposing longitudinaledges of the absorbent core 142. However it is to be appreciated thatthe vacuum zones may be configured with different lateral widths and maydefine lateral widths that are larger or smaller than what is depicted.For example, some embodiments may include vacuum zones having lateralwidths that are equal to or greater than the lateral widths of theabsorbent core and/or chassis. In addition, the conveyors may also beconfigured with more than one vacuum zone along the cross direction CDand/or machine direction MD.

As the diaper pant 100P advances in the machine direction through thetucking zone, the opposing vacuum forces exerted by the first and secondconveyors 502 and 504 may continue to hold the chassis or may be removedfrom the chassis. And a side panel tucker 516 pushes the side panels 112and 114 into the chassis 102, such as shown for example in FIG. 13. Asthe side panels 112 and 114 are pushed into the chassis 102, the innersurfaces 132 of the first waist region 116 and the second waist region118 may move toward each other. Tucking the side panels 112 and 114 intothe chassis 102 also creates longitudinal fold lines 250 and 252 in thechassis 102. In the configuration shown in FIG. 13, the longitudinalfold lines 250 and 252 may also coincide with and may be defined by thelongitudinal side edges of the absorbent core 142. It is to beappreciated that the longitudinal fold lines 250 and 252 may be createdin various different locations depending on the particular tuckingmethod and configuration. For example, in some embodiments, thelongitudinal fold lines may correspond with lateral side edges of thevacuum zones. In some embodiments, the side panels may not be completelytucked inside the chassis, and as such, the longitudinal fold lines maybe defined along the lengths of the side panels.

It is to be appreciated that side panel tuckers 516 may be configured invarious different ways. For example, as shown in FIG. 14, the side paneltuckers 516 are configured as rotating blades 518. As the diaper pant100P advances in the machine direction past the side panel tuckers 516,a rotating blade or blades may impinge on each of the side panels 112and 114 and push the side panels into the chassis 102. In anotherembodiment, shown in FIG. 15, the side panel tuckers 516 are configuredas air jets 520. As the diaper pant 100P advances in the machinedirection past the side panel tuckers 516, air discharged in the crossdirection, CD, from the air jets 520 may impinge on each of the sidepanels 112 and 114 and push the side panels into the chassis 102. In yetother embodiments, the side panel tuckers 516 may be configured as railsthat converge toward each other in the cross direction, CD. The sidepanel tuckers may be in contact with the absorbent article over thecomplete machine direction length between the vacuum zone or zonescreated by the first conveyor 502 and second conveyor 504 through thenon-vacuum zone to the vacuum zone or zones created by the firstconveyor 502. The side panel tuckers may be oriented in an overlappingorientation with one or more conveyors in the machine direction.Overlapping the side panel tucker and the conveyors may help maintainthe side panels in a tucked position until the absorbent article isfully folded, i.e. interior surface 132 in the first waist region 116 isin contact with the interior surface 132 in the second waist region 118.In sill other embodiments, the side panel tuckers may be configured asone of the aforementioned devices that also discharges air to push theside panels into the chassis. For example, the side panel tuckers may beconfigured to discharge air from rotating blades, blades that travel ontracks, and/or converging rails. Other side panel tucker configurationsare disclosed in U.S. Pat. Nos. 6,723,035 and 6,776,316.

Once the side panels 112 and 114 are pushed into the chassis 102, thediaper pant 100P may continue to advance on the first conveyor 502 inthe machine direction. The waist regions 116 and 118 of the diaper pant100P may also be further compressed together to help hold the sidepanels 112 and 114 in the tucked position, such as with conveyors thatconverge toward each other in the machine direction.

It is to be appreciated that the converting apparatus can be placed inother configurations to manufacture diaper pants having various otherfeatures. For example, FIG. 10 shows the converting apparatus 300 in athird, pant diaper, configuration that may be adapted to produce pantdiapers 100P with side seams, such as shown and described above withrespect to FIGS. 3, 6, and 7. As discussed above with respect to FIGS. 8and 9, a relatively large percentage of transformations also remain thesame in the taped configurations of FIG. 8 and the pant configuration ofFIG. 10.

As mentioned above with respect to FIG. 8, it is to be appreciatedtransformations shown and described in FIG. 10 can be carried out invarious different orders than that which is depicted and describedherein. As shown in FIG. 10, when the converting apparatus 300 is placedin the third configuration for producing pant diapers 100P, the topsheetassembly process 1001, core assembly 1002, and leg cuff assembly andassociated transformations 2001 and 2002 may be the same as discussedabove with reference to the taped diaper configuration shown in FIG. 8.In addition, the backsheet assembly 1004, leg elastic assembly 1005 andassociated transformations 2003 and 2007 shown in FIG. 10 may be thesame as discussed above with reference to FIG. 8. As such, thetransformations associated with the process assemblies 1001, 1002, 1003,1004 and 1005 discussed above with reference FIGS. 8A and 8B may also bethe same as transformations associated with the process assemblies 1001,1002, 1003, 1004 and 1005 shown in the pant diaper configuration of FIG.10.

Although many of the processes and associated transformations may remainunchanged between the taped diaper configuration shown in FIG. 8 and thepant diaper configuration shown in FIG. 10, there are some differences.For example, in FIG. 10, the landing zone assembly 1008T and associatedtransformation 2006T are shown in dashed lines to indicate theseassemblies and transformations are not used in the pant diaperconfiguration. In some embodiments of the converting apparatus 300, thetransformation mechanisms associated with 1008T and 2006T need not bephysically removed from the converting apparatus, but rather, simplydisabled or “turned-off” when the converting mechanism is placed in thepant configuration.

As shown in FIG. 10, the converting apparatus in the second, pantdiaper, configuration may include a rear ear panel assembly process1006P and a front ear panel assembly 1007P to create rear ear panels 112b and 114 b and front ear panels 112 a and 114 a, such as shown in FIG.3. The rear ear panels 112 b and 114 b and front ear panels 112 a and114 b may also be combined with the backsheet substrate attransformations 2004P and 2005P, respectively. It is to be appreciatedthat the ear panel assembly processes 1006P and 1007P may also includevarious transformations. For example, the rear ear panel assemblyprocess 1006P and the front ear panel assembly process may include theidentical transformations as discussed above with reference to the backear assembly process 1006T and front ear assembly process 1007T shown inFIGS. 8 and 8B. In other embodiments, a relatively large ear panel canbe added using the transformations of the back ear assembly process1006T or the front ear assembly process 1007T, wherein the large earpanel is later cut at the final knife 2009 into the back ear panel andthe front ear panel.

As discussed above with reference to FIGS. 8 and 9, as shown in FIG. 10,the final forming process 1009 also may include some differenttransformations depending on whether the converting apparatus is in thefirst, taped diaper, configuration or the second, pant diaper,configuration. For example, the ear folding transformation 2008T shownin FIG. 8 is removed when the converting apparatus 300 is placed in thepant configuration shown in FIG. 10. As such, when the pant diapers 100Pin FIG. 10 advance past the final knife transformation 2009, the frontear panels 112 a and 114 a and rear ear panels 112 b and 114 b areextended laterally outward from the longitudinal side edges 128, 130 ofthe chassis 102, such as shown in FIG. 3. In addition, as shown in FIG.10, the pant diapers 100P are subject to the same folding transformation2010 as described with reference to the taped diaper configuration inFIG. 8. As such, the converting apparatus 300 may utilize the samefolding apparatus 302, such as described above, whether operating in thetaped diaper configuration or the pant diaper configuration shown inFIG. 10. However, when the pant diapers 100P are folded 2010, the frontear panels 112 a and 114 a and rear ear panels 112 b and 114 b remain inlaterally extended positions.

As shown in FIG. 10, the folded pant diapers 100P are subjected toadditional transformations not applied to the taped diapers 100T. Inparticular, the folded pant diapers 100P are subjected to a side panelconnection transformation 2012 and a side panel tucking transformation2013 before advancing to the stacking transformation 2011. The sidepanel tucking transformation 2013 and associated mechanisms may the sameas discussed above with reference to FIG. 9. However, the side panelconnection transformation 2012 in FIG. 10 may have some difference fromthat discussed above with reference to FIG. 9.

When the folded pant diapers 100P advance from the foldingtransformation 2010 and through the side panel connection transformation2012, the distal end regions 176 a of the laterally extending front earpanels 112 a and 114 a are connected with the distal end regions 176 bof the rear ear panels 112 b and 114 b, such as shown for example inFIGS. 3 and 6. As such, the side panel connection transformation 2012 ofFIG. 10 may be configured to connect the distal end regions 176 a of thefront ear panels 112 a and 114 a with the distal end regions 176 b ofthe rear ear panels 112 b and 114 b along side seams 178 and 180. It isto be appreciated that various types of transformation mechanisms may beused to carry out the side panel connection 2012 in FIG. 10. Forexample, the distal end regions 176 a and 176 b may pass through bondingnips, such as high pressure rolls to refastenably or permanently bondthe distal end regions with glue, cohesives, mechanical bonds,ultra-sonic bonds, mechanical fasteners, and the like.

It is to be appreciated that the laterally opposing side seams 178, 180may be disposed at or adjacent the side edge 128, 130 in one or bothwaist regions 116, 118. In embodiments wherein the lateral extent of thefront waist region 116 is substantially equal to the lateral extent ofthe back waist region 118 during bonding of the permanent side edgeseams 178, 180, the side edge seams may be disposed at or adjacent theside edges of the absorbent article in both the front and back waistregions. In the embodiment, the absorbent article is folded at alaterally extending fold line disposed in the crotch region to bring thefront waist region and the back waist region into an interior surface tointerior surface face to face orientation. The permanent side edge seamsare formed by placing the interior surface of one waist regions in anoverlapping relationship with the exterior surface of the opposing waistregion adjacent the side edges and subsequently bonding the waistregions together. The first fastening component may be applied to thearticle prior to forming the permanent side edge seam. The secondfastening component may also be applied prior to forming the permanentside edge seam or after forming the permanent side edge seam. In thisembodiment, the first fastening component and the non-engagement surfaceare disposed at least partially within the permanent side edge seam withthe fastening surface of the first fastening component in a face to facesurface to surface orientation with the non-engagement surface. Asremoved from the package, the absorbent article is in the form of apant. The user may apply the absorbent article to the wearer as a pantor alternatively the user may apply the absorbent article as a tapeddiaper by first releasing the fastening component by separating thefront waist region from the back waist region by breaking the permanentside edge seam thereby opening the initial waist opening circumference,then placing the back waist region of the article under the wearer andfastening the first fastening component to the second fasteningcomponent to reclose the pant on the wearer.

It is to be appreciated that in some embodiments, the convertingapparatus may be configured such that changing from the first, tapeddiaper, configuration the second (or third), pant diaper, configurationmay require the removal, replacement, and/or installation of varioustransformation mechanisms. Some such mechanisms may be associated withthe final forming process 1009. However, in other embodiments, theconverting apparatus may be configured with alternate diaper travelpaths in the final forming process such that changing from the first,taped diaper, configuration the second (or third), pant diaper,configuration does not require the removal, replacement, and/orinstallation of various transformation mechanisms associated with thefinal forming process 1009.

FIG. 8C shows an example flow diagram showing various transformationsthat may be used to construct a taped diaper as well as a pant diaper.In a first configuration, 70 separate transformations are used toproduce a first product, in this example a taped diaper. In a secondconfiguration, 50 separate transformations are used to produce a secondproduct, in this example a pant diaper. Of the 50 transformationsutilized in the second configuration, 48 of those transformations, 96%,are the same as the transformations utilized in the first configuration.The plain boxes shown are the transformations that are present in both afirst configuration, taped diaper, and a second configuration, pantdiaper. The boxes with a 1 are those that are present only in a firstconfiguration, taped diaper, and may be simply turned off or bypassed inthe second configuration, pant diaper. The boxes with a 2 are thosepresent in only the second configuration, pant diaper. It is to beappreciated that other converting line arrangements may have a firstconfiguration with a first number of transformations and a secondconfiguration with a second number of transformations, wherein variouspercentages of the first and second numbers of transformations are thesame transformations. For example, in some embodiments, 70% or greaterof the second number of transformations used in a second configurationmay be the same transformations used in the first configuration. Inanother example, 80% or greater of the second number of transformationsused in a second configuration may be the same transformations used inthe first configuration. In yet another example, 90% or greater or even95% or greater of the second number of transformations used in a secondconfiguration may be the same transformations used in the firstconfiguration.

In order to make two different product types, for example pant diapersand taped diapers, on the same converting line or converting linescomprising similar transformations, it may be important to maintain theline speeds for each of the product types within a specified operatingline speed range. The converting lines are typically comprised ofmultiple transformations each of which may have a centerline definingits optimum operating condition and an operating range around thecenterline where the transformation can operate without significantchanges or modifications. Therefore, producing both taped and pantproducts on lines having common transformations requires a specificoperating range derived as a function of overall line speed, productsper minute. The following ranges have been established for productshaving a pitch length, length of the product along the longitudinalcenterline, of between 480 mm to 550 mm. It should be understood thatfor a given linear speed the line speed, products per minute, willincrease for shorter products and decrease for longer products.

For processes wherein one of the taped or pant diaper products isproduced at a first line speed of less than 800 products per minute, theoperating line speed range for the other product is defined as the firstline speed+/−50%. In other words if a taped diaper is made at 500products per minute then the pant diaper must be produced at a speed ofbetween 250 products per minute and 750 products per minute. Preferablyif the processes wherein one of the taped or pant diaper products isproduced at a first line speed of less than 800 products per minute, theoperating line speed range for the other product is defined as the firstline speed+/−25%. In other words if a taped diaper is made at 600products per minute then the pant diaper must be produced at a speed ofbetween 450 products per minute and 750 products per minute.

For processes wherein one of the taped or pant diaper products isproduced at a first line speed of between 800 and 960 products perminute, the operating line speed range for the other product is definedas the first line speed+/−30%. In other words if a taped diaper is madeat 900 products per minute then the pant diaper must be produced at aspeed of between 630 products per minute and 1170 products per minute.Preferably if the processes wherein one of the taped or pant diaperproducts is produced at a first line speed of between 800 and 960products per minute, the operating line speed range for the otherproduct is defined as the first line speed+/−10%. In other words if ataped diaper is made at 900 products per minute then the pant diapermust be produced at a speed of between 810 products per minute and 990products per minute.

For processes wherein one of the taped or pant diaper products isproduced at a first line speed of greater than 960 products per minute,the operating line speed range for the other product is defined as thefirst line speed+/−20%. In other words if a taped diaper is made at 1000products per minute then the pant diaper must be produced at a speed ofbetween 800 products per minute and 1200 products per minute. Preferablyif the processes wherein one of the taped or pant diaper products isproduced at a first line speed of greater than 960 products per minute,the operating line speed range for the other product is defined as thefirst line speed+/−5%. In other words if a taped diaper is made at 1000products per minute then the pant diaper must be produced at a speed ofbetween 950 products per minute and 1050 products per minute.

Maintaining the process or processes within the desired operating linespeed range may help minimize the down time to make adjustments betweentaped and pant products and will maximize the overall efficiency andsynergy of the process. In addition, it may help simplify developmentsince each of the multiple transformations needs to only be developedfor one type of product and subsequently can be reapplied to the secondtype of product.

It is to be appreciated that various types of pant and taped diapers maybe constructed in accordance with the aforementioned methods andapparatuses. As such, embodiments of such apparatuses and methods may beconfigured to construct pant and taped diapers having some elements thatare configured with specified ranges of performance parameters.

In some embodiments, pant and taped diapers having inner leg cuffs maybe constructed in accordance with the above-described methods andapparatuses, wherein the inner leg cuffs are configured to have a rangeof force characteristics, as described below. In one form, such as shownin FIGS. 16-18, an inner leg cuff may include a rectilinear specimen ofa SMS (Spunbond-Meltblown-Spunbond) hydrophobic nonwoven 600 with abasis weight of about 15 g/m², commonly known as Securon® manufacturedby Fiberweb, which is cut with a CD width dimension, A, and a MD lengthdimension, B, shown in FIG. 16. In some embodiments, A may be 52 mm, andB may be 488 mm, wherein the long axis, B, of the specimen 600 isparallel to the machine direction MD of the nonwoven material, and theshort axis, A, of the specimen 600 is parallel to the cross direction CDof the nonwoven material. As shown in FIG. 16, the specimen of nonwoven600 has a first machine direction edge 602, a second machine directionedge 604, a first cross direction edge 606, and a second cross machinedirection edge 608.

As shown in FIG. 17A, adhesive 610 (Bostik H2031) is applied in a spiralpattern at a basis weight of 9.3 g/m² uniformly in an area 612 definedby dimension, C, in the cross direction and by dimension, D, in themachine direction. In some embodiments, dimension C may be 8 mm, anddimension D may be 312 mm. The adhesive area 612 is aligned so that afirst longitudinal edge 614 is located in a cross direction distance, E,from the first machine direction edge 602, and a first lateral edge 616is offset by distance, F, in a machine direction from the first crossmachine direction edge 606 as shown in FIG. 17A. In some embodiments,distance E may be 10 mm, and distance F may be 75 mm. The adhesive 610is applied at a suitable elevated temperature directly to the nonwovensubstrate 600 (a mask may be used to obtain the desired adhesive area),or alternatively the adhesive 610 may be applied to silicone-coatedrelease paper and transferred to the nonwoven 600 at room temperatureafter cutting the appropriate sized piece.

As shown in FIG. 17B, two elastic strands 618 (Invista 680 decitex LycraT262P) each 135.5 mm long in their relaxed state are stretched uniformlyto 488 mm (i.e. 260% extension) and adhesively bonded to the nonwoven600 parallel to the first machine direction edge 602 of the specimen 600by pressing the stretched strands 618 onto the specimen. A first elasticstrand 618 may be located a distance, G, from the first machinedirection edge 602, and the second elastic strand 618 may be located adistance, H, first machine direction edge 602. In some embodiments,distance G may be 11 mm, and distance H may be 13 mm. A ¼″ (6.35 mm)wide by 488 mm strip of double sided tape identified as Medical TransferAdhesive 1524 manufactured by the 3M Company is applied to the specimen600 so that the nearest edge of the adhesive 620 is parallel to andlocated distance, J, from the first machine direction edge 602. In someembodiments, distance J may be 2 mm. The second machine direction edge604 of the nonwoven 600 is lifted and folded over the stretched elasticstrands 618 and double sided tape 620 so that a fold line 622 is locateda distance, K, from the first machine direction edge 602 as shown inFIG. 17B. In some embodiments, distance K may be 18 mm.

A cross section of the sample is shown in FIG. 18. Using a hand roller,an adequate pressure is applied to the entire specimen to make sure theadhesives 610, 620 bond to the elastics 618 and nonwoven 600. Thenonwoven 600 is bonded to the inner surface (e.g. a topsheet) of adiaper having a pitch length of 488 mm so that the cuff spans the entirelength of the diaper. The inner cuff may be attached to the innersurface of the diaper 7 mm from any outer cuff or margin, substantiallyparallel to the longitudinal axis of the diaper, so that the inner cuffis attached along a line 30 mm from the fold line in the inner cuff. Theinner leg cuff may be attached to the chassis of a taped or pant diaperby any means known to the art, such as for example, pressure, heat, andultrasonic bonding.

The inner cuff specimen is tested according to the method for InnerCuffs in the Cuff Tensile Test described in the Test Methods sectionbelow. In one embodiment of an inner cuff specimen that may be appliedto a taped or pant diaper, the force value on the 2^(nd) unload cycle at85% extension may be between 0.25 N and 0.45 N and/or the strain valueat 0.05 N on the 2^(nd) unload cycle may be between 50% and 75%.

In some embodiments, pant and taped diapers having outer leg cuffs maybe constructed in accordance with the above-described methods andapparatuses, wherein the outer leg cuffs are configured to have a rangeof force characteristics, as described below. In one form, such as shownin FIGS. 19-22, an outer leg cuff may include a rectilinear specimen 700of a SMS (Spunbond-Meltblown-Spunbond) hydrophobic nonwoven with a basisweight of about 15 g/m², commonly known as Securon® manufactured byFiberweb, is cut with a CD width dimension, L, and a MD lengthdimension, M, shown in FIG. 19. In some embodiments, dimension L may be40 mm and dimension M may be 488 mm, so that the long axis, M, of thespecimen is parallel to the machine direction MD of the nonwovenmaterial. The specimen of nonwoven 700 has a first machine directionedge 702 and a second machine direction edge 704, a first crossdirection edge 706, and a second cross machine direction edge 708, asshown in FIG. 19.

An adhesive 710 (Bostik H2031) is applied in a spiral pattern at a basisweight of 11 g/m² uniformly in an area 712 defined by dimension, N, inthe cross direction and by dimension, O, in the machine direction (amask may be used to obtain the desired adhesive area), or alternativelythe adhesive 712 may be applied to silicone-coated release paper andtransferred to the nonwoven 700 at room temperature after cutting theappropriate sized piece. In some embodiments, dimension N may be 15 mm,and dimension O may be 276 mm. The adhesive area 712 is aligned so afirst longitudinal edge 714 is located a distance, P, from the firstmachine direction edge 702 of the nonwoven 700 and a first lateral edge716 is offset a distance, Q, from the first cross direction edge 706, asshown in FIG. 20A. In some embodiments, distance P may be 12.5 mm, anddistance Q may be 85 mm. The adhesive 710 is applied at a suitableelevated temperature directly to the nonwoven substrate 700 (a mask maybe used to obtain the desired adhesive area), or alternatively theadhesive 710 may be applied to silicone-coated release paper andtransferred to the nonwoven at room temperature after cutting theappropriate sized piece. Three elastic strands 718 (Invista 680 decitexLycra T262P) each 143.5 mm long in their relaxed state are stretcheduniformly to 488 mm (i.e. 240% extension) and adhesively bonded to thenonwoven 700 parallel to the machine direction edge 702 of the specimen700 spaced a distance, R, apart and centered on the nonwoven 700 in thecross direction as seen in FIG. 20B. In some embodiments, distance R maybe 3 mm.

A suitable breathable backsheet film 800 layer with a basis weight of 16g/m² such as a MicroPro™ Microporous Film available through ClopayPlastic Products is cut with a CD width dimension, S, and a MD lengthdimension, T, shown in FIG. 21. In some embodiments, dimension S may be40 mm and dimension T may be 488 mm, so that the long axis, T, of thespecimen is parallel to the machine direction MD of the backsheet filmmaterial. The specimen of backsheet film 800 has a first machinedirection edge 802, a second machine direction edge 804, a first crossdirection edge 806, and a second cross machine direction edge 808, asshown in FIG. 21. The backsheet film layer 800 is then applied to theassembled elastics 718 and cuff material 700 so that the first machinedirection edges 702, 802 and the first cross machine direction edges706, 806 of the nonwoven 700 and backsheet film 800 are aligned with thestretched elastics 718 between the nonwoven 700 and backsheet film 800,as shown in FIG. 22. Using a hand roller, adequate pressure is appliedto the entire sample to make sure the adhesives 710 bond to the elastics718, nonwoven 700, and backsheet film layers 800.

The outer cuff is tested according to the method for Outer Cuffs in theCuff Tensile Test described in the Test Methods section below. The forcevalue on the 2^(nd) unload cycle at 85% extension may be between 0.35 Nand 1.0 N and/or the strain value at 0.05N on the 2^(nd) unload cyclemay be between 60% and 80%.

In still another form, pant diapers having waist openings may beconstructed in accordance with the above-described methods andapparatuses, wherein the waist openings are configured to have a rangeof force characteristics that may be measured according to the WaistStretch Test (Pants) recited below. In some embodiments, the waist hooplength at 2000 gf may be between 200 and 800 mm; may be between 500 and700 mm; and may be from 550 to 670 mm and/or the unload force at a waisthoop length of 530 mm may be between 250 and 2000 gf; may be between 300and 1500 gf; and may be between 350 and 1150 gf.

In yet another form, taped diapers having back ears may be constructedin accordance with the above-described methods and apparatuses, whereinthe back ears are configured to have a range of force characteristicsthat may be measured according to the Waist Stress-Relaxation Test(Taped Diapers) recited below. In some embodiments, the elongationvalues at 4N force during the loading cycle may be between 30 mm and 110mm; may be between 50 mm and 100 mm; and may be between 70 mm and 90 mm.The elongation values at 10N force during the loading cycle may bebetween 60 mm and 180 mm; may be between 100 mm and 165 mm; and may bebetween 135 mm and 150 mm. The force at 60 minutes, F₆₀, after reachingthe maximum elongation as described below according to Step 2 of theWaist Stress-Relaxation Test (Taped Diapers) may be greater than 45% ofthe maximum force, F_(max), which may be measured at the maximumelongation.

Test Methods Section

Cuff Tensile Test

A suitable tensile tester such as an MTS Alliance with MTS Testworksversion 4.0 or equivalent instrument is used. The tester is equippedwith grips that are at least as wide as the width of specimens to betested, lined with one rubber-coated face and one contact line face forboth upper and lower grips. A load cell is used so that the maximum loadmeasured is within 10-90% of the maximum capacity of the load cell. Theinstrument is calibrated according to the manufacturer's specification.

Pitch Length

A disposable product is held in a flat horizontal configuration by tapesor other suitable means. Two cuts are made along the entire length ofthe product 12.5 mm on either side of the longitudinal centerline. Eachstraight cut is made vertically through the entire product along itslength from the front edge to the rear edge. The central 25 mm widestrip is removed and the topsheet is cut along the transversecenterline. The length of the specimen along the longitudinal centerlineis determined to within ±1 mm under minimal tension. This is themeasured pitch length of the product. The adjusted pitch length is themeasured pitch length minus the combined length of any material heldabove or below the upper and lower grip lines in the tensile tester,respectively. Thus, if a specimen is mounted in the tensile tester sothat 10 mm at each end of the specimen protrudes past the contact linein the clamps, then the adjusted pitch length is the measured pitchlength minus 20 mm.

Outer Cuffs:

A disposable product is held in a flat horizontal configuration by tapesor other suitable means. Outer cuff specimens are cut from the productusing a sharp blade. The cuts are made parallel to the longitudinalcenterline of the product between the inner and outer cuffs so that thespecimens contain all of the outer cuff elastics, but none of the innercuff material. Each straight cut is made vertically through the entireproduct along its entire length from the front edge to the rear edge,and all material in the specimen in addition to the cuff (including anynonwoven, topsheet, glue, core, backsheet, etc) is retained in thespecimen.

Inner Cuffs:

A disposable product is held in a flat horizontal configuration by tapesor other suitable means. Inner cuff specimens are cut from the productusing a sharp blade. The entire inner cuffs are cut along the length ofthe product immediately above the bond joining the cuff to the topsheet,backsheet or other diaper component.

Testing is performed at 23° C.±2° C. and 50%±2% relative humidity.

Test Procedure:

The gauge length is set to enable the specimen to be mounted withminimal slack so that approximately 10 mm at each end of the specimenprotrudes past the contact line in the clamp. The load cell must readbetween 0 and 0.04 N of force after mounting the sample. If the valueexceeds 0.04 N, then the gauge length is reduced in 1 mm incrementsuntil the force is between 0 and 0.04 N. A 5.0 gram-force pre-load isapplied to the specimen using a crosshead speed of 0.5 inches/minute.The adjusted gauge length of the specimen is the distance between thegrip lines when the five gram pre-load is reached. The sample is thenextended to 95% of the adjusted pitch length at 254 mm/min (1^(st) loadcycle), and held at that elongation for 5 seconds. The crosshead is thenreturned to the adjusted gauge length at 254 mm/min (1^(st) unloadcycle) and held for 5 seconds. The sample is again extended to 95% ofthe adjusted pitch length at 254 mm/min (2^(nd) load cycle), and held atthat elongation for 5 seconds. The crosshead is then returned to theadjusted gauge length at 254 mm/min (2^(nd) unload cycle).

Waist Stretch Test (Pants)

A suitable tensile tester such as an MTS Alliance with MTS Testworksversion 4.0 or equivalent is used. The tester is equipped withhook-shaped fixtures 900A, 900B according to the dimensions specified inFIG. 23. The fixtures 900A, 900B are mounted and aligned on the tensiletester so that the arms A and B as shown in FIG. 24 are horizontal andlie in the same vertical plane. A load cell is used so that the maximumload measured is within 10-90% of the maximum capacity of the load cell.The instrument is calibrated according to the manufacturer'sspecification. Testing is performed at 23° C.±2° C. and 50%±2% relativehumidity.

Test Procedure:

Step 1:

A sample product is removed from its package and carefully opened toavoid stretching any portion of the product. The crosshead of thetensile tester is raised to a point where the product can be mounted onthe upper fixture arm by inserting the free end of the arm through thewaist opening of the product, and then through a first leg opening, sothat the product hangs freely from the upper arm. The product ispositioned on the arm so that the side-panel is centered with respect tothe vertical axis of the load cell.

The load cell of the instrument is tared with the product hanging freelyfrom the upper arm. The crosshead is then lowered to a point where thelower fixture arm can be inserted through the waist opening of theproduct and then through the second leg opening without stretching anyportion of the product. The product is positioned so that both sidepanels are centered with respect to the vertical axis of the load cell,and there is no tension in the waist of the product (i.e. there is slackin the waist). The crosshead is then moved up at a speed of 254 mm/minuntil a load of 2000 gf is obtained (1^(st) cycle load), and theposition of the crosshead is recorded. The crosshead is stopped and heldfor 30 seconds, then returned to its original position at a speed of 254mm/min (1^(st) cycle unload).

Waist Stress-Relaxation Test (Taped Diapers)

A suitable tensile tester such as an MTS Alliance with MTS Testworksversion 4.0 or equivalent instrument is used. The tester is equippedwith grips that are at least as wide as the width of specimens to betested, lined with one rubber-coated face and one contact line face forboth upper and lower grips. A load cell is used so that the maximum loadmeasured is within 10-90% of the maximum capacity of the load cell. Theinstrument is calibrated according to the manufacturer's specification.

Testing is performed at 23° C.±2° C. and 50%±2% relative humidity.

Test Procedure:

Step 1:

A sample product is removed from its package and carefully opened toavoid stretching any of the waist or side-panel materials. The gaugelength of the tensile tester is set to 30 mm less than the width of theproduct at a line bisecting the tape tabs when the product is laid flatwithout stretching any of the waist or side-panel materials. This is thebase gauge length. The tape tabs are opened and each tape is mounted ina separate grip on the tensile tester with the grip line immediatelyadjacent the bond attaching the tape to the rest of the product.

A 5.0 gram-force pre-load is applied to the sample using a crossheadspeed of 0.5 inches/minute. When the five gram pre-load is reached thisis the adjusted gauge length. The sample is then immediately extended ata crosshead speed of 508 mm/min [20 in/min] (load cycle) until a forceof 15 N is observed. The crosshead is then stopped and returned to thebase gauge length at a speed of 508 mm/min (unload cycle), and thesample is removed from the grips. The elongation values at 4 N and 10 Nduring the load cycle, based on the adjusted gauge length, are recorded.ΔL _(4N)=(gauge length at 4 N during load cycle)−(adjusted gauge length)ΔL _(10N)=(gauge length at 10 N during load cycle)−(adjusted gaugelength)

Step 2:

A second identical product is removed from its package and carefullyopened to avoid stretching any of the waist or side-panel materials. Thetape tabs are opened and each tape is mounted in a separate grip on thetensile tester at the base gauge length as described in Step 1 above.The sample is then extended at a crosshead speed of 508 mm/min (loadcycle) until the same % elongation is achieved as in Step 1, based onthe adjusted gauge length in Step 1. The crosshead is then stopped andheld in this position for 60 minutes. The maximum force observed duringthe Step 2 load cycle (F_(max)), and the force at 60 minutes afterreaching the maximum % elongation in Step 2 (F₆₀) are recorded.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

Every document cited herein, including any cross referenced or relatedpatent or application, is hereby incorporated herein by reference in itsentirety unless expressly excluded or otherwise limited. The citation ofany document is not an admission that it is prior art with respect toany invention disclosed or claimed herein or that it alone, or in anycombination with any other reference or references, teaches, suggests ordiscloses any such invention. Further, to the extent that any meaning ordefinition of a term in this document conflicts with any meaning ordefinition of the same term in a document incorporated by reference, themeaning or definition assigned to that term in this document shallgovern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. Disposable absorbent articles constructed usingtransformations that are at least 70% the same, comprising: a tapedarticle in a first package comprising a first chassis, a front waistregion and a back waist region, wherein the back waist region compriseslaterally opposed ear flaps joined to side edges of the first chassis,wherein proximal side edges of the ear flaps comprise fasteners, whereinthe fasteners are not fastened to form a waist opening, such that thetaped article is configured as an open diaper in the first package; andwherein the fasteners extend laterally across the laterally opposed earflaps; a pant article in a second package comprising a second chassis, afront waist region and a back waist region, wherein a front belt flap isjoined to the front waist region and a back belt flap is joined to theback waist region, and wherein side edges of the front and back beltsare joined to form laterally opposed permanent side seams, thus forminga waist opening and leg openings, such that the pant article isconfigured as a pre-closed diaper in the second package; wherein thelaterally opposed permanent side seams do not comprise fasteners;wherein the first and second chassis are at least identical to theextent that: each of the first and second chassis comprise identicalchemical compositions of one or more of a topsheet, backsheet film,backsheet nonwoven, core super absorbent polymers, core pulp, corenonwoven, core tissue, leg cuff film, leg cuff nonwoven, super absorbentpolymer adhesive, core nonwoven adhesive, leg cuff elastic adhesive, andbacksheet nonwoven/film adhesive; and each of the first and secondchassis comprise the same basis weight of one or more of the topsheet,backsheet film, backsheet nonwoven, core super absorbent polymers, corepulp, leg cuff nonwoven, leg cuff film, super absorbent polymeradhesive, leg cuff adhesive, and backsheet nonwoven/film adhesive;wherein the front belt flap comprises a first end edge and a second endedge and a folded edge that forms a portion of the waist opening of thepant article, and wherein the first end edge of the front belt flap isdisposed longitudinally outboard of the second end edge of the frontbelt flap and longitudinally inboard of the folded edge of the frontbelt flap; and wherein the back belt flap comprises a first end edge anda second end edge and a folded edge that forms a portion of the waistopening of the pant article, and wherein the first end edge of the backbelt flap is disposed longitudinally outboard of the second end edge ofthe back belt flap and longitudinally inboard of the folded edge of theback belt flap; wherein a first portion the first end edge of the frontbelt flap overlaps the second chassis from a first side edge of thesecond chassis to a second side edge of the second chassis, and whereinthe first portion of the first end edge of the front belt flap is joinedto an interior surface of the second chassis, and wherein a secondportion of the first end edge of the front belt flap does not overlapthe second chassis and is joined to an interior surface of the frontbelt flap; and wherein the second end edge of the front belt flapoverlaps the second chassis from the first side edge of the secondchassis to the second side edge of the second chassis and is joined toan exterior surface of the second chassis.
 2. The disposable absorbentarticles of claim 1, wherein the ear flaps comprise an elastomeric film.3. The disposable absorbent articles of claim 1, wherein the front andback belt flaps comprise a plurality of elastomeric strands disposedtransverse to a longitudinal axis of the pant article.
 4. The disposableabsorbent articles of claim 3, wherein the front and back belt flaps ofthe pant article comprise elastomeric film.
 5. The disposable absorbentarticles of claim 1, wherein the first and second chassis are at leastidentical to the extent that the first and second chassis have at leastone identical component cross sectional order and disposition of atopsheet, backsheet, core, including the core wrap, in at least one thefront waist region, back waist region, and crotch region.
 6. Thedisposable absorbent articles of claim 1, wherein the first packagecomprises indication of a first size, and wherein said second packagecomprises indication of a second size, wherein said first and secondsizes are different.
 7. The disposable absorbent articles of claim 6,wherein the first package comprises size X articles and the secondpackage comprises size X+1 articles.
 8. The disposable absorbentarticles of claim 1, wherein the first package comprises size X articlesand the second package comprises size X−1 articles.
 9. The disposableabsorbent articles of claim 1, wherein each of the first and secondchassis comprise absorbent gelling material, and wherein the absorbentgelling material of each are compositionally identical.
 10. Thedisposable absorbent articles of claim 9, wherein the absorbent gellingmaterial of each chassis is adhered to each chassis with compositionallyidentical adhesive.
 11. The disposable absorbent articles of claim 1,wherein the first and second chassis are at least identical to theextent that the first and second chassis have identical component crossdisposition of a topsheet, backsheet, core, including the core wrap, inthe crotch region.
 12. The disposable absorbent articles of claim 1,wherein the first and second chassis are at least identical to theextent that the first and second chassis have identical component crosssectional order and disposition of a topsheet, backsheet, core,including the core wrap, in the front waist region and the back waistregion.
 13. The disposable absorbent articles of claim 1, wherein theaverage chassis width of the articles of the first package issubstantially the same as the average chassis width of the articles ofthe second package.
 14. The disposable absorbent articles of claim 1,wherein a first portion the first end edge of the back belt flapoverlaps the second chassis from the first side edge of the secondchassis to the second side edge of the second chassis, and wherein thefirst portion of the first end edge of the back belt flap is joined tothe interior surface of the second chassis, and wherein a second portionof the first end edge of the back belt flap does not overlap the secondchassis and is joined to an interior surface of the back belt flap; andwherein the second end edge of the back belt flap overlaps the secondchassis from the first side edge of the second chassis to the secondside edge of the second chassis and is joined to an exterior surface ofthe second chassis.
 15. The disposable absorbent articles of claim 14,wherein the back belt flap has a greater longitudinal distance at oradjacent to a side seam formed between the front and back belt flap thanthe longitudinal distance at or adjacent to the side seam of the frontbelt flap.
 16. The disposable absorbent articles of claim 1, wherein thefirst chassis comprises a waistband disposed inboard of side edges thefirst chassis, wherein the waistband is discrete from the first chassis.17. The disposable absorbent articles of claim 1, wherein the backsheetsof the first and second articles are substantially the same width. 18.The disposable absorbent articles of claim 1, wherein core wraps of thefirst and second articles are in the same configuration.
 19. Thedisposable absorbent articles of claim 1, wherein the backsheets of thetaped and pant articles have substantially the same moisture vaportransmission rate and hydrohead.
 20. The disposable absorbent articlesof claim 1, wherein the first and second chassis are at least identicalto the extent that each of the first and second chassis compriseidentical chemical compositions of each of the topsheet, backsheet film,backsheet nonwoven, core super absorbent polymers, core pulp, corenonwoven, core tissue, leg cuff film, leg cuff nonwoven, super absorbentpolymer adhesive, core nonwoven adhesive, leg cuff elastic adhesive, andbacksheet nonwoven/film adhesive.
 21. The disposable absorbent articlesof claim 20, wherein the first and second chassis are at least identicalto the extent that each of the first and second chassis comprise thesame basis weight of each of the topsheet, backsheet film, backsheetnonwoven, core super absorbent polymers, core pulp, leg cuff nonwoven,leg cuff film, super absorbent polymer adhesive, leg cuff adhesive, andbacksheet nonwoven/film adhesive.
 22. The disposable absorbent articlesof claim 1, wherein the first and second chassis are at least identicalto the extent that each of the first and second chassis comprise thesame basis weight of each of the topsheet, backsheet film, backsheetnonwoven, core super absorbent polymers, core pulp, leg cuff nonwoven,leg cuff film, super absorbent polymer adhesive, leg cuff adhesive, andbacksheet nonwoven/film adhesive.
 23. Disposable absorbent articlesconstructed using transformations that are at least 70% the same,comprising: a taped article in a first package comprising a firstchassis, a front waist region and a back waist region, wherein the backwaist region comprises laterally opposed ear flaps joined to side edgesof the first chassis, wherein proximal side edges of the ear flapscomprise fasteners, wherein the fasteners are not fastened to form awaist opening, such that the taped article is configured as an opendiaper in the first package; and wherein the fasteners extend laterallyacross the laterally opposed ear flaps; a pant article in a secondpackage comprising a second chassis, a front waist region and a backwaist region, wherein a front belt flap is joined to the front waistregion and a back belt flap is joined to the back waist region, andwherein side edges of the front and back belts are joined to formlaterally opposed permanent side seams, thus forming a waist opening andleg openings, such that the pant article is configured as a pre-closeddiaper in the second package; wherein the laterally opposed permanentside seams do not comprise fasteners; wherein the first and secondchassis are at least identical to the extent that: each of the first andsecond chassis comprise identical chemical compositions of one or moreof a topsheet, backsheet film, backsheet nonwoven, core super absorbentpolymers, core pulp, core nonwoven, core tissue, leg cuff film, leg cuffnonwoven, super absorbent polymer adhesive, core nonwoven adhesive, legcuff elastic adhesive, and backsheet nonwoven/film adhesive; and each ofthe first and second chassis comprise the same basis weight of one ormore of the topsheet, backsheet film, backsheet nonwoven, core superabsorbent polymers, core pulp, leg cuff nonwoven, leg cuff film, superabsorbent polymer adhesive, leg cuff adhesive, and backsheetnonwoven/film adhesive; wherein the front belt flap comprises a firstend edge and a second end edge and a folded edge that forms a portion ofthe waist opening of the pant article, and wherein the first end edge ofthe front belt flap is disposed longitudinally outboard of the secondend edge of the front belt flap and longitudinally inboard of the foldededge of the front belt flap; and wherein the back belt flap comprises afirst end edge and a second end edge and a folded edge that forms aportion of the waist opening of the pant article, and wherein the firstend edge of the back belt flap is disposed longitudinally outboard ofthe second end edge of the back belt flap and longitudinally inboard ofthe folded edge of the back belt flap; wherein a first portion the firstend edge of the back belt flap overlaps the second chassis from thefirst side edge of the second chassis to the second side edge of thesecond chassis, and wherein the first portion of the first end edge ofthe back belt flap is joined to the interior surface of the secondchassis, and wherein a second portion of the first end edge of the backbelt flap does not overlap the second chassis and is joined to aninterior surface of the back belt flap; and wherein the second end edgeof the back belt flap overlaps the second chassis from the first sideedge of the second chassis to the second side edge of the second chassisand is joined to an exterior surface of the second chassis.
 24. Thedisposable absorbent articles of claim 23, wherein the first and secondchassis are at least identical to the extent that each of the first andsecond chassis comprise identical chemical compositions of each of thetopsheet, backsheet film, backsheet nonwoven, core super absorbentpolymers, core pulp, core nonwoven, core tissue, leg cuff film, leg cuffnonwoven, super absorbent polymer adhesive, core nonwoven adhesive, legcuff elastic adhesive, and backsheet nonwoven/film adhesive.
 25. Thedisposable absorbent articles of claim 24, wherein the first and secondchassis are at least identical to the extent that each of the first andsecond chassis comprise the same basis weight of each of the topsheet,backsheet film, backsheet nonwoven, core super absorbent polymers, corepulp, leg cuff nonwoven, leg cuff film, super absorbent polymeradhesive, leg cuff adhesive, and backsheet nonwoven/film adhesive. 26.The disposable absorbent articles of claim 23, wherein the first andsecond chassis are at least identical to the extent that each of thefirst and second chassis comprise the same basis weight of each of thetopsheet, backsheet film, backsheet nonwoven, core super absorbentpolymers, core pulp, leg cuff nonwoven, leg cuff film, super absorbentpolymer adhesive, leg cuff adhesive, and backsheet nonwoven/filmadhesive.